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GENERAL INFORMATION     1-3

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* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures not require use of bat-

tery power, disconnect the negative cable the battery.

* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and

other fluids: batteries, and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

Содержание 2002 DL1000K2

Страница 1: ...DL1000...

Страница 2: ...re your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then difference...

Страница 3: ...on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and othe...

Страница 4: ...olant 99000 99032 11X Apply molybdenum oil solution Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99001 SS8 Apply SUZUKI SUPER GREASE A 99000 25010 Apply or use brak...

Страница 5: ...de CPU Central Processing Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit...

Страница 6: ...kcase Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position...

Страница 7: ...ATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT 1 5 WATER FOR MIXING 1 5 ANTI FREEZE ENGINE COOLANT 1 5 LIQUID AMOUNT...

Страница 8: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper...

Страница 9: ...nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O...

Страница 10: ...equired especially for registering the machine and ordering spare parts FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL FOR CANADIAN MODEL Use only unleaded gasoline of at least 87 pump octane or 91 o...

Страница 11: ...not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AM...

Страница 12: ...ercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 4 500 r min Up to 1 600 km 1 000 miles Below 7 000 r min Over 1...

Страница 13: ...ng label For E 33 5 Fuel caution label For E 02 24 6 Manual notice label For E 03 33 7 Tire pressure label 8 Warning safety label 9 Rear carrier warning label 0 Frame caution label A Steering warning...

Страница 14: ...rs 2 Bore 98 0 mm 3 858 in Stroke 66 0 mm 2 598 in Piston displacement 996 cm 60 8 cu in Compression ratio 11 3 1 Fuel system Fuel injection system Air cleaner Non woven fabric element Starter system...

Страница 15: ...e phase A C Generator Fuse 30 15 15 15 15 15 10 A Headlight 12 V 60 55 W H4 Position light 12 V 5 W 2 Except for E 03 24 28 33 Turn signal light 12 V 10 W License light 12 V 5 W Brake light Taillight...

Страница 16: ...MATION COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA E 02 E 03 E 19 E 24 E 28 E 33 U K U S A Except for California EU Australia Canada...

Страница 17: ...HOSE 2 12 ENGINE OIL AND OIL FILTER 2 12 ENGINE IDLE SPEED 2 14 THROTTLE CABLE PLAY 2 14 THROTTLE VALVE SYNCHRONIZATION 2 15 PAIR AIR SUPPLY SYSTEM 2 15 CLUTCH 2 16 COOLING SYSTEM 2 17 DRIVE CHAIN 2 1...

Страница 18: ...18 24 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance I Spark plugs I R I R Fuel hose I I I I Replace every 4 years Engine oil R R R R R Engine oil filter R R I...

Страница 19: ...ore lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle h...

Страница 20: ...of removal Inspect every 6 000 km 4 000 miles 6 months and replace every 18 000 km 11 000 miles 18 months Always use air pressure on the throttle body side of the air cleaner element If air pressure...

Страница 21: ...plug mounting bolts A and B Move the radiator forward Remove the spark plug cap 1 NOTE Be careful not to damage the radiator fins Remove the spark plug with a spark plug wrench Inspect every 6 000 km...

Страница 22: ...Measure the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap 09900 20803 Thickness gauge Spark plug gap A Standard 0 6 0 7 mm 0 024 0 028 in ELECTRODES CONDITION...

Страница 23: ...on 2 when the valve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Tappet clearance when cold IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in...

Страница 24: ...a thickness gauge between the tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge Turn the crankshaft 270 degrees turns to set t...

Страница 25: ...ometer to ensure its size Refer to the tappet shim selection table Pages 2 10 and 11 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be su...

Страница 26: ...2 10 PERIODIC MAINTENANCE INTAKE SIDE...

Страница 27: ...PERIODIC MAINTENANCE 2 11 EXHAUST SIDE...

Страница 28: ...nd drain oil by removing the drain plug 1 and filler cap 2 Tighten the drain plug 1 to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 7 L 2 9 2 4 US Imp qt...

Страница 29: ...ntil you feel that the fil ter gasket contacts the mounting surface Then tighten it 2 turns using the oil filter wrench 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the specia...

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