Suzuki SV1000K5 Supplementary Service Manual Download Page 1 | Manualshive

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Summary of Contents for SV1000K5

Page 1: ...USETHE MANUALWITH SV1OOOWSVIOQO SERVICE MANUAL 99500 39251 WE...

Page 2: ...m s m m m m m m m m m m m 5 SERVICE DATA SVlOOOK5 7 SERVICE DATA SVfW S K S 16 CRANKCASE CRANKSHAFT BEARING SELEG770hl 25 Fi SYSTEM WRING DIAGRAM 26 ECM TERIMtNAL Fur K4 Model 27 ECM TERMINAL For KWo...

Page 3: ...r AREA U K USA ExceptforCalifornia Canada California U S A E U Australia EFFECTIVE FRAMENO i 200100001 SV1OMSK5 JS1BX412200100001 SV1OOOKS SV1000SK5 JSIVT54A 52100001 SV1WOK5 JS18x431100100001 SV1000U...

Page 4: ...ight Turn signal light Brake lighnail tight Speedometer light TachwneTer l i f t Fuel level indicatorlight Turn signel indicator light Neutralindicator light High beam indicator light Oil pressurelCoo...

Page 5: ...33 17 L 4 513 7 USlrnp gal Others Englneoil nil change 2 700 rnl 2 912 4USlrnp qt w th f lter change 2 900ml 3 112 6 USllmp qt overhaul 3 300ml 3512 9 USllmp qt Cmlant 2 2 L 2 Y1 4Uslmp qt These ylec...

Page 6: ...ke Rear brake Front tire size Rear tlre size ELECTRICAL Ignitionl y p Ignitiont ming Spark plug Battery Generalor Mainfuse Fuse Headlight Position light Licenseplate ligM Turn signal 119111 Brake I gh...

Page 7: ...gal E 33 17L 4 93 7 USnrnpgal Oltiers Eqined al change 2300rnl 2 912 4 USllrnpqt wrth filter change 2 900rnl 3 1 2 6 USllmpqt overhaul 3300rnt 3 5 2 9 INtmp qt Coolant 2 2 L 2 31 9US lmpqt Thems p k t...

Page 8: ...adial runout Valve springfree length Valve spring tension IN EX IN EX IN EX CAMSHAFT CYLINDER HEAD Unit mm in ITEM STANDARD LIMIT 197 227 N 20 1 23 1kgf 44 3 51 0lbs at length 35 6 rnm 1 40in Camshaft...

Page 9: ...ated Compression pressuredifference Piston diarn Cylinderdistortion STANDARD 1 050 1 450 kPa 10 5 14 5 kgf crn2 149 206 psi Piston ringfree end gap LIMIT 850kPa 8 5kgf cm2 121psi Piston ring end gap P...

Page 10: ...739 1 741 Conrod bis end oil clearance 6 040 0 064 0 080 0 0016 0 0625 0 0031 OIL PUMP Crank pin O D Crankshaftjournal oil clearance Crankshaftjournal O D Crankshaft runout CLUTCH Unit mm tin 44 976...

Page 11: ...N COOLANT r a 11 DalvE TRAIN 4 A Shiftfork thickness Drive chain Drive chain slack Gearshift lever height 4 8 4 9 0 189 0 193 319 4 12 6 Type Links 20 link length I i RKSOSMOZ1 110 links ENDLESS 20 30...

Page 12: ...ITEM Injector resistance I SPECIFICATION 11 13I1at20 C 68OF Fuel pump discharge amount 168 ml and more 5715 9 USArnp oz for 70 seconds at 300 kPa 3 0kgf cm2 43 psi Fuel pressure regulator operating s...

Page 13: ...GK CR8EK DENSO V24ETR 0 6 0 7 0 024 0 028 Over 8 0 3 at 1 atm 130 240f2 Crankshaft positionsensor peak voltage Ignition coil primary peak voltage Generatorcoil resistance Generator Max output Generato...

Page 14: ...indicator light Fuel indicator light Coolant temperaturelOilpressure FI indicator l ght License light Brake disc runout Front Rear Master cylinder bore Master cylinder piston diarn 0 30 0 012 Rear Fro...

Page 15: ...orberspring pre set length Rear shock absorber damping force adjuster Rear wheel travel Swingarm pivot shaft runout 298 11 7 120 4 7 305 12 0 149 15 81 SUZUKl FORK O I L LO1 or an equivalent fork oil...

Page 16: ...el type psi 36 I kgflcm2 2 50 kPa 250 Use only unleaded gasoline of at least 87 pump octane R 2 M12 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl E...

Page 17: ...23 1kgf 44 3 51 0Ib at length 35 6 mm 1 40 in 41 2 1 62 LIMIT 37 48 1 476 I 36 88 1 452 ITEM Cam height Camshaftjournal oil clearance Camshaftjournal holder I D Camshaftjournal O D STANDARD IN UC 37 7...

Page 18: ...iston ring groovewidth 0 93 0 95 0 0366 0 0374 1st 1 55 1 57 0 0610 0 0618 1 01 1 03 0 0398 0 0406 I Piston ring thickness Piston pin bore I D Piston pin O D LIMIT 0 10 0 004 0 05 0 002 STANDARD IN EX...

Page 19: ...FT Unit mrn in OIL PUMP Crankshaftrunout 0 05 0 002 CLUTCH Unit mm in LIMIT E M STANDARD rive plate thickness Oil pressure at 60 C 140 OF Above 350 kPa 3 5 kgflcm2 50 psi Below650kPa 6 5kgflcm2 92 psi...

Page 20: ...to groove clearance Gear ratio Low 2 666 132112 1 838 57131 2 352 40117 1 227 27122 1 086 25123 1 OOO 24124 0 1 0 3 0 50 0 004 0 012 0 020 Drive chain slack Gearshift lever height Shift fork groove wi...

Page 21: ...ORS NOTE ITEM Injector resistance Fuel pump dischargeamount Fuel pressure regulator operating set pressure SPEClflCATlON 11 1312at20nC 68 F 168 rnl and more 5 715 9 USAmp oz for 10seconds at 300 kPa 3...

Page 22: ...R Over 8 0 3 at 1 atm I NOTE 5 0 V and more When cranking I Ignitioncoil primary peak voltage 1 200 V and more I When crankina tap tap tap Plug cap Primary Secondary 1Generator coil resistance 1 0 2 0...

Page 23: ...inder bore 0 18 0 30 0 012 p p 0 1 97 i t 0 008 Leading Trailing Front Rear Front Rear Front Rear Front Rear 15 870 15 913 0 6248 0 6265 14 000 14 043 0 5512 0 5529 15 827 15 854 0 6231 0 6242 13 957...

Page 24: ...SUSPENSION w Unit mm in...

Page 25: ...he research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 etha nol or less than 5 methanol with appropriate cosolvents and corrosion inhibitoris permissible Gasoline used sh...

Page 26: ...Bearingthickness I D code 9 A B C 1 Bearing must be replacedas a set I P specification 52 000 52 006 mrn 2 0472 2 0475 in 52 006 52 012 mm 2 0475 2 0477 in 52 012 52 018 mm 2 0477 2 0479in Color Part...

Page 27: ...FI SYSTEM WIRING DIAGRAM...

Page 28: ...I ECM TERMINAL For KCModel...

Page 29: ...ECM TERMINAL For K5 Model...

Page 30: ...he engine can start and can run even if the above signal is not receivedfrom each sensor But the engine hb running condition is not complete providing only emergency help byfail safe circuit In thisca...

Page 31: ...wire coupler connec tion C17 is indicated The sensor should produce following voltage 0 50 V 5 sensor voltage 4 85 V Without the above range C17 is indicated lntake air pressure sensor wiringlcoupler...

Page 32: ...on signal but fuel injection signal is intempted continuous by 4 times or more Inthis case the codeC32or C33 is indicated Injector wiringlcoupler connection power supply to the injector No voltage is...

Page 33: ...ltage resistanceor continu ily at the ECMterminal are locatedas shown below NOTE Tomeasure vmge resistance or continuity of sensors the terminalson fhe wiring harness side should be used with the wiri...

Page 34: ...3 1 1 1 1 1 m 9 4 m m a m 1 IL C21 IAT SENSOR CIRCUIT MALFUNCTION 2 ECM coupler Wiring harness s de C L F J 1 1 1 1 1 1111 a a C23 TO SENSOR CIRCUIT MALFUNCTION 2 ECMcoupler Wiringharnessside c 3 29 C...

Page 35: ...CIRCUIT MALFUNCTION ECM coupler Wiring harness side c 3 m m m E c a n n n m n n m n n n 3 2 or C33 FUEL INJECTOR CIRCUIT MALFUNCTION ECM coupler Wiring harness side 3 31 e C41 FP RELAY CIRCUIT MALFUNC...

Page 36: ...I C44 H02 SENSOR H02S CIRCUIT MALFUNCTlON For E 02 19 I I 3 J ECMcoupler Wiringhamesaslde 2 9 C49 PAIR CONTROL SOLENOID VALVE 2 ECMewrpler Wiring h e mslde I...

Page 37: ...seal stopper ring 11 Oil seal retainer Guide metal Front fork cap bolt lnner rod lock nut ic Front axle pinch bolt ib Damper rod bolt h FRONT FORK SPRING When installing the front fork spring the clos...

Page 38: ...ator switch as shown in the right illustrations The bulb should come on after several seconds if the switch is in gmd condition L When the switch is immersed in kerosine under the above con dition the...

Page 39: ...WIRING HARNESS ROUTING For SV1000K5 H02sensor For E 02 19...

Page 40: ...er instdetriangre area betweenthe kame and fender Set the high tensioncord rear side as much as possible without contact with the fuel tank Set the harnessof the handle L inside of each hoses Insideof...

Page 41: ...ROTTLE CABLE ROUTING For SVi000K5 Throttle cable No 1 Throttlecabk No 2 Passthe throttle cables in front of the brake hose Throttlecable No 1 Throttle caMe No 2 rmlecabb No 1 SECT A A Throttle able No...

Page 42: ...THROTTLE BODY INSTALLATIONNOSE ROUTING Intake Forward 6 Purge hose E 33 pipe side Alr cleaner side hose Marking White...

Page 43: ...42 SVlO00K51SK5 REAR BRAKE HOSE ROUTING For SV1000K5...

Page 44: ...REAR BRAKE HOSE ROUTING For SV1000SK5...

Page 45: ...1 SUZUKl MOTOR CORPORATION Decernher 2004 Part No 99501 39560 03E Printed in U S A...

Page 46: ...NDICATOR LIGHT L B HI BEAM INDICnTOA LIGHT N NEUTRAL INDlCATOR L l G M e F FUEL LEVEL INDICATOR LIGHT 0 OIL TEMP FIINDICATOR LIGHT PRESSURE SPEEDOMETER SWITCH FRONtfVRH SIGNAL LIO SWlTC Bunon TURN SIG...

Page 47: ...n LtCElYSEUGHT REARTURNSIGNAL LIGHT R BRAKEUOHTrrAlLLlGHT REAR TURN SIOPIAL LIGHT C FUSE BOX I WEAD CR 10 A 2 HEADLO 1 0 R VALVE STARTER S FVEL 10A MMllR 4 l G N m 15 A SIDE STAND 5 SfGHAL I O A SWITC...

Page 48: ...WIRING DIAGRAM SV1000K5 For E 24 331...

Page 49: ...m P R V SWITCH u ECM BRAKE L1OHIFAlLLlQHT REARTURN 51ONAL LMHT L S E W R SPEE POSIHON SWlTCn N S E BOX r nuom IOA 2 HEAOLO l a FUEL 104 4 IGNITION 15 A SIDE STAND 5 SIGNAL t0A S W I T C 6 FAN 15A...

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