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Suzuki SV1000 Service Manual

Manual is about: Motorcycle

Summary of SV1000

  • Page 1

    9 9 5 0 1 - 3 9 5 4 0 - 0 1 e sv1000 use this manual with: sv1000s service manual (99500-39250-01e).

  • Page 2: Sv1000K3

    Sv1000k3 1 contents sv1000k3 © copyright suzuki motor corporation 2003 foreword this manual describes service data, service specifications and servicing procedures which dif- fer from those of the sv1000sk3. Note: * any differences between the sv1000sk3 (’03-model) and sv1000k3 in specifications and...

  • Page 3: Specifications

    2 sv1000k3 specifications dimensions and dry mass overall length....................................................... * 2 135 mm (84.1 in) overall width ........................................................ * 785 mm (30.9 in) overall height..........................................................

  • Page 4

    Sv1000k3 3 chassis front suspension................................................. Telescopic, coil spring, oil damped rear suspension ................................................. Link type, coil spring, oil damped front suspension stroke ...................................... 120 mm (4.7 in)...

  • Page 5: Periodic Maintenance

    4 sv1000k3 periodic maintenance chassis bolt and nut check that all chassis bolts and nuts are tightened to their specified torque. (refer to below and page 2-29 of sv1000s service manual for the locations of the following nuts and bolts on the motorcycle.) chassis front fork remounting • align the ...

  • Page 6

    Sv1000k3 5 suspension setting after installing the front fork, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment there are eight grooves on the spring adjuster. Position 1 pro- vides the maximum spring pre-load and position 8 provides the minimum spring pre-load. St...

  • Page 7

    6 sv1000k3 handlebars removal and disassembly • remove the handlebar balancer 1. Note: do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. • remove the rear view mirror ...

  • Page 8

    Sv1000k3 7 • remove the handlebars by removing the handlebar clamp bolts. Reassembly and remounting • install the handlebars with the punch mark a aligned with the mating surface b of the handlebar holder. • set the punch mark c on the handlebar clamp forward. • tighten the handlebar clamp bolts to ...

  • Page 9

    8 sv1000k3 • install the left handlebar switch to the handlebars by engaging the stopper 5 with the handlebar hole 6. • install the clutch master cylinder. ( #sv1000s 6-94 and below) • install the handlebar balancers and rear view mirrors. (handlebar balancer installation: #16) master cylinder remou...

  • Page 10

    Sv1000k3 9 wiring harness, cable and hose routing wiring harness routing set the coupler center of the frame. Ignition coil set the speed sensor coupler under the clutch hose. Clutch hose cable guide throttle cables harness handle switch (l) clamp starter motor battery - clamp the lead wire under th...

  • Page 11

    10 sv1000k3 horn set the connector and harness between the frame and reservoir tank. Set surely. Clamp wiring harness neutral switch clamp the harness without contact to the bracket. Set the high tension cord rear side as much as possible without contact with the fuel tank. Taping clamp speedometer ...

  • Page 12

    Sv1000k3 11 throttle cable routing sect a view b b a a pass the throttle cable no. 1 upper the no. 2 . 0 mm 0 mm throttle cable no. 1 throttle cable no. 2 guide harness handle switch (lh) clutch hose guide pass the throttle cables in front of the brake hose. Guide throttle cable no. 1 throttle cable...

  • Page 13

    12 sv1000k3 clutch hose routing a c view a after the clutch hose union touching to the stopper, tighten the union bolt. 21˚ 14˚ b b c c after the clutch hose union touching to the stopper, tighten the union bolt. B frame bridge after positioning the clutch hose with the frame bridge, tighten the cla...

  • Page 14

    Sv1000k3 13 front brake hose routing 28 ˚ 21 ˚ a b p ass through the br ak e hose into the guide . P ass the br ak e hose behind the throttle cab les . View a view b sect e view c inser t the clamp to the hole in front of the f ender fully . Clamp view d e e after positioning the clamp with the stop...

  • Page 15

    14 sv1000k3 rear brake hose routing after the br ak e hose union touching to the stopper , tighten the union bolt. F ace the clamp ends bac kw ard. The white paint f aces outside . View a view d view b view c a b d c f ace the clamp ends bac kw ard. Br ak e hose 35 ˚ be careful not to contact the se...

  • Page 16

    Sv1000k3 15 brake pedal/footrest set-up pin e-r ing spacer spr ing f ootrest br ac k e t br ak e retur n spr ing br ak e light s witch spr ing a a br ak e pedal rear br ak e master cylinder cotter pin sect a e-r ing f ootrest f ootrest holder br ak e pedal f ootrest br ac k e t sect b b b rear br ak...

  • Page 17

    16 sv1000k3 prop stay set-up handle balancer installation clamp up fuel tank prop stay fuel tank prop stay forward fuel tank prop stay rear fender no. 1 rear fender no. 2 lift and support the fuel tank with its prop stay. Up lh clearance a is 0 mm. Rh clearance a is 0.5 – 1.5 mm. Note: after install...

  • Page 18: Tightening Torque

    Sv1000k3 17 tightening torque chassis item n·m kgf-m lb-ft steering stem head nut 90 9.0 65.0 steering stem lock nut 80 8.0 58.0 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork inner rod lock nut 15 1.5 11.5 front fork damper...

  • Page 19

    18 sv1000k3 item n·m kgf-m lb-ft steering damper bolt 23 2.3 16.5 steering damper nut 23 2.3 16.5 steering stem nut 45 4.5 32.5.

  • Page 20: Service Data

    Sv1000k3 19 service data valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 36 (1.42) — ex. 33 (1.30) — tappet clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) — ex. 0.20 – 0.30 (0.008 – 0.012) — valve guide to valve stem clear- ance in. 0.010...

  • Page 21

    20 sv1000k3 cylinder + piston + piston ring unit: mm (in) item standard limit cam drive idle gear/sprocket thrust clearance 0.15 – 0.29 (0.006 – 0.011) — cylinder head distortion — 0.05 (0.002) item standard limit compression pressure (automatic de-comp. Actuated) 1 000 – 1 400 kpa (10 – 14 kgf/cm 2...

  • Page 22

    Sv1000k3 21 conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 22.010 – 22.018 (0.8665 – 0.8668) 22.040 (0.8677) conrod big end side clearance 0.17 – 0.32 (0.007 – 0.013) 0.50 (0.020) conrod big end width 21.95 – 22.00 (0.864 – 0.866) — crank pi...

  • Page 23

    22 sv1000k3 thermostat + radiator + fan + coolant drive train unit: mm (in) expect ratio item standard limit thermostat valve opening tem- perature 86.5 – 89.5 °c (188 – 193 °f) — thermostat valve lift over 8.0 mm (0.31 in) at 100 °c (212 °f) — radiator cap valve opening pressure 110 kpa (1.1 kgf/cm...

  • Page 24

    Sv1000k3 23 injector + fuel pump + fuel pressure regurator fi-sensors item specification note injector resistance 11 – 13 Ω at 20 °c (68 °f) fuel pump discharge amount 168 ml and more (5.7/5.9 us/lmp oz) for 10 seconds at 300 kpa (3.0 kgf/cm 2 , 43 psi) fuel pressure regulator operat- ing set pressu...

  • Page 25

    24 sv1000k3 throttle body electrical unit: mm (in) item specification id no. * 16g1 (for e-33), 16g2 (others) bore size 52 mm fast idle r/min 1 900 – 2 500 r/min at 25 °c (77 °f) idle r/min 1 200 ± 100 r/min/warmed engine throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firi...

  • Page 26

    Sv1000k3 25 wattage unit: w brake + wheel unit: mm (in) item specification headlight hi 60 lo 55 position light (for e-02, 19) 5 brake light/taillight led turn signal light 21 × 4 speedometer/tachometer light led turn signal indicator light led high beam indicator light led neutral indicator light l...

  • Page 27

    26 sv1000k3 suspension unit: mm (in) tire pressure item standard limit wheel rim runout (front & rear) axial — 2.0 (0.08) radial — 2.0 (0.08) wheel axle runout front — 0.25 (0.010) rear — 0.25 (0.010) wheel rim size front 17m/c × mt 3.50 — rear 17m/c × mt 5.50 — tire size front 120/70 zr17m/c (58w),...

  • Page 28

    Sv1000k3 27 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with appropriate c...

  • Page 29

    Wiring diagram e-02, 19 lg b/w y b/w b/bl b b/w b b/w g/y bl/b b o/g r/w o/g b/w o/r p/w br/b b/g b/w y/b lg y b/o b o/w w/bl o/w b/br w/g w/b w gr b w y/b o/w r/w y/r r br/w b/br b/br g/y r b w/bl b/w br/b gr/w gr/b br w/b r/w r bl/g y/w b/w dg o/g g/b g/y b/y p/w b/r y/g r/b b/br w/g b/w g/bl bl/b...

  • Page 30

    E-03, 24, 28, 33 lg b/w y b/w b/bl b b/w b b/w g/y bl/b b o/g r/w o/g b/w o/r p/w br/b b/g b/w y/b lg y b/o b o/w w/bl y/b o/w r/w y/r r br/w b/br b/br g/y r b w/bl b/w br/b gr/w gr/b br r/w r bl/g y/w b/w dg o/w g/b g/y b/y p/w b/r y/g r/b b/w g/bl bl/b y/r gr/r g p y/b o/r b/br b/w b/bl b/g bl/w w...

  • Page 31

    Prepared by may, 2003 part no. 99501-39540-01e printed in japan 28.

  • Page 32

    Printed in japan k3.