Suzuki DL1000 VStrom 2002 2003 2004 2005 2006 2007 2008 2009 Factory Service Repair Manual + Wiring Diagrams

Suzuki DL1000 VStrom 2002 2003 2004 2005 2006 2007 2008 2009 Factory Service Repair Manual + Wiring Diagrams

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Suzuki. 

444 Pages

MODEL YEAR:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

MODEL COVERS:

Suzuki DL1000 VStrom

MANUAL COVERS:

GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FI SYSTEM 4
COOLING AND LUBRICATION
SYSTEM 5
CHASSIS 6
ELECTRICAL SYSTEM 7
SERVICING INFORMATION 8
EMISSION CONTROL
INFORMATION 9
WIRING DIAGRAM

PERIODIC MAINTENANCE SCHEDULE ……………………………………..2- 2
PERIODIC MAINTENANCE CHART …………………………………….2- 2
LUBRICATION POINTS ………………………………………………………2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ………………………….2- 4
AIR CLEANER …………………………………………………………………..2- 4
SPARK PLUG ……………………………………………………………………2- 5
TAPPET CLEARANCE ……………………………………………………….2- 7
FUEL 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 ……………………………………………………………………2-19
BRAKE ……………………………………………………………………………..2-21
TIRE …………………………………………………………………………………2-25
STEERING ………………………………………………………………………..2-25
FRONT FORK ……………………………………………………………………2-26
REAR SUSPENSION ………………………………………………………….2-26
EXHAUST PIPE BOLT ………………………………………………………..2-26
CHASSIS BOLT AND NUT ………………………………………………….2-27
COMPRESSION PRESSURE CHECK ………………………………………….2-29
COMPRESSION TEST PROCEDURE …………………………………..2-29
OIL PRESSURE CHECK …………………………………………………………….2-30
OIL PRESSURE TEST PROCEDURE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE …3- 2
ENGINE REMOVAL AND INSTALLATION …………………………………..3- 3
ENGINE REMOVAL ……………………………………………………………3- 3
ENGINE INSTALLATION …………………………………………………….3-12
ENGINE DISASSEMBLY ……………………………………………………………3-19
ENGINE TOP SIDE …………………………………………………………….3-19
ENGINE BOTTOM SIDE ……………………………………………………..3-25
ENGINE COMPONENTS INSPECTION AND SERVICING ……………..3-34
CYLINDER HEAD COVER ………………………………………………….3-34
CAMSHAFT/CYLINDER HEAD ……………………………………………3-35
CYLINDER/PISTON INSPECTION ……………………………………….3-47
CONROD/CRANKSHAFT ……………………………………………………3-50
CLUTCH ……………………………………………………………………………3-54
TRANSMISSION ………………………………………………………………..3-56
GEARSHIFT FORK …………………………………………………………….3-62
PRIMARY DRIVE GEAR ……………………………………………………..3-63
STARTER TORQUE LIMITER ……………………………………………..3-64
STARTER CLUTCH ……………………………………………………………3-65
GEARSHIFT ………………………………………………………………………3-66
CRANKCASE …………………………………………………………………….3-66
CRANKCASE-CRANKSHAFT BEARING ……………………………..3-71
GENERATOR COVER ………………………………………………………..3-77
CLUTCH COVER ……………………………………………………………….3-77
GEARSHIFT COVER ………………………………………………………….3-77
ENGINE REASSEMBLY …………………………………………………………….3-78
ENGINE BOTTOM SIDE ……………………………………………………..3-78
ENGINE TOP SIDE …………..

PRECAUTIONS IN SERVICING ……………………………………………………………4- 2
CONNECTOR/COUPLER …………………………………………………………….4- 2
FUSE …………………………………………………………………………………………4- 3
ECM/VARIOUS SENSORS …………………………………………………………..4- 3
ELECTRICAL CIRCUIT INSPECTION PROCEDURE ……………………..4- 5
USING TESTERS ………………………………………………………………………..4- 8
FI SYSTEM TECHNICAL FEATURES ……………………………………………………4- 9
INJECTION TIME (INJECTION VOLUME) ……………………………………..4- 9
COMPENSATION OF INJECTION TIME (VOLUME) ……………………….4-10
INJECTION STOP CONTROL ………………………………………………………4-10
FUEL DELIVERY SYSTEM ………………………………………………………….4-11
FUEL PUMP ……………………………………………………………………………….4-12
FUEL PRESSURE REGULATOR ………………………………………………….4-13
FUEL INJECTOR ………………………………………………………………………..4-13
FUEL PUMP CONTROL SYSTEM ………………………………………………..4-14
ECM (FI CONTROL UNIT) ……………………………………………………………4-15
INJECTION TIMING …………………………………………………………………….4-15
SENSORS ………………………………………………………………………………….4-16
FI SYSTEM PARTS LOCATION ……………………………………………………………4-20
FI SYSTEM WIRING DIAGRAM ……………………………………………………………4-22
SELF-DIAGNOSIS FUNCTION ……………………………………………………………..4-23
USER MODE ………………………………………………………………………………4-23
DEALER MODE ………………………………………………………………………….4-24
TPS ADJUSTMENT …………………………………………………………………….4-25
FAIL-SAFE FUNCTION ………………………………………………………………………..4-26
FI SYSTEM TROUBLESHOOTING ……………………………………………………….4-27
CUSTOMER COMPLAINT ANALYSIS ………………………………………….4-27
SELF-DIAGNOSTIC PROCEDURES …………………………………………….4-29
SELF-DIAGNOSIS RESET PROCEDURE ……………………………………..4-29
MALFUNCTION CODE AND DEFECTIVE CONDITION …………………..4-30
“C11” CMP SENSOR CIRCUIT MALFUNCTION ……………………………4-32
“C12” CKP SENSOR CIRCUIT MALFUNCTION …………………………….4-33
“C13” IAP SENSOR CIRCUIT MALFUNCTION ……………………………..4-34
“C14” TP SENSOR CIRCUIT MALFUNCTION ……………………………….4-36
“C15” ECT SENSOR CIRCUIT MALFUNCTION …………………………….4-38
“C21” IAT SENSOR CIRCUIT MALFUNCTION ……………………………..4-39
“C22” AP SENSOR CIRCUIT MALFUNCTION ………………………………4-40
“C23” TO SENSOR CIRCUIT MALFUNCTION ………………………………4-42
“C24” or “C25” IGNITION SYSTEM MALFUNCTION …………………….4-43
“C28” STV ACTUATOR CIRCUIT MALFUNCTION ………………………..4-43
“C29” STP SENSOR CIRCUIT MALFUNCTION …………………………….4-44
“C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION …..4-46
“C32” or “C33” FUEL INJECTION MALFUNCTION ……………………….4-47
“C41” FP RELAY CIRCUIT MALFUNCTION ………………………………….4-48
“C42” IG SWITCH CIRCUIT MALFUNCTION ………………………………..4-48
“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION ………………….4-49
FUEL SYSTEM ……………………………………………………………………………………4-51
2 4 6
FI SYSTEM 4-1
FUEL TANK LIFT-UP …………………………………………………………………..4-51
FUEL TANK REMOVAL ……………………………………………………………….4-52
FUEL TANK INSTALLATION ……………………………………………………….4-52
FUEL PRESSURE INSPECTION …………………………………………………..4-53
FUEL PUMP INSPECTION …………………………………………………………..4-54
FUEL PUMP RELAY INSPECTION ……………………………………………….4-55
FUEL PUMP AND FUEL FILTER REMOVAL …………………………………4-55
FUEL MESH FILTER INSPECTION AND CLEANING ……………………..4-57
FUEL PUMP AND FUEL MESH FILTER INSTALLATION ………………..4-57
THROTTLE BODY AND STV ACTUATOR ……………………………………………..4-59
CONSTRUCTION ………………………………………………………………………..4-59
THROTTLE BODY REMOVAL ……………………………………………………..4-60
THROTTLE BODY DISASSEMBLY ………………………………………………4-61
THROTTLE BODY CLEANING ……………………………………………………..4-65
INSPECTION ………………………………………………………………………………4-65
THROTTLE BODY REASSEMBLY ……………………………………………….4-65
STP SENSOR ADJUSTMENT ………………………………………………………4-68
THROTTLE BODY INSTALLATION ………………………………………………4-69
TP SENSOR ADJUSTMENT …………………………………………………………4-69
FUEL INJECTOR INSPECTION ……………………………………………………4-69
FUEL INJECTOR REMOVAL ……………………………………………………….4-70
FUEL INJECTOR INSTALLATION ………………………………………………..4-70
FAST IDLE INSPECTION …………………………………………………………….4-70
FAST IDLE ADJUTMENT …………………………………………………………….4-71
THROTTLE VALVE SYNCHRONIZATION ……………………………………..4-72
THROTTLE CABLE ADJUSTMENT ………………………………………………4-73
SENSOR …………………………………………………………………………………………….4-74
IAP SENSOR INSPECTION ………………………………………………………….4-74
IAP SENSOR REMOVAL/INSTALLATION …………………………………….4-74
TP SENSOR INSPECTION …………………………………………………………..4-74
TP SENSOR REMOVAL/INSTALLATION ………………………………………4-74
STP SENSOR INSPECTION …………………………………………………………4-74
STP SENSOR REMOVAL/INSTALLATION ……………………………………4-74
CKP SENSOR INSPECTION ………………………………………………………..4-75
CKP SENSOR REMOVAL/INSTALLATION ……………………………………4-75
CMP SENSOR INSPECTION ………………………………………………………..4-75
CMP SENSOR REMOVAL/INSTALLATION …………………………………..4-75
IAT SENSOR INSPECTION ………………………………………………………….4-75
IAT SENSOR REMOVAL/INSTALLATION ……………………………………..4-75
ECT SENSOR INSPECTION …………………………………………………………4-76
ECT SENSOR REMOVAL/INSTALLATION ……………………………………4-76
AP SENSOR INSPECTION …………………………………………………………..4-76
AP SENSOR REMOVAL/INSTALLATION ……………………………………..4-76
TO SENSOR INSPECTION …………………………………………………………..4-76
TO SENSOR REMOVAL/INSTALLATION ……………………………………..4-76
HO2 SENSOR INSPECTION …………………………………………………………4-76
HO2 SENSOR REMOVAL/INSTALLATION …………………………………….4-77

ENGINE COOLANT ……………………………………………………………………5- 2
COOLING CIRCUIT ……………………………………………………………………5- 3
COOLING CIRCUIT INSPECTION ……………………………………….5- 3
RADIATOR ……………………………………………………………………………….5- 4
REMOVAL …………………………………………………………………………5- 4
INSPECTION AND CLEANING ……………………………………………5- 5
INSTALLATION …………………………………………………………………5- 6
RADIATOR RESERVOIR TANK ………………………………………………….5- 6
REMOVAL/INSTALLATION ………………………………………………..5- 6
RADIATOR CAP ………………………………………………………………………..5- 6
INSPECTION ……………………………………………………………………..5- 6
WATER HOSE …………………………………………………………………………..5- 7
INSPECTION ……………………………………………………………………..5- 7
COOLING FAN ………………………………………………………………………….5- 8
REMOVAL …………………………………………………………………………5- 8
INSPECTION ……………………………………………………………………..5- 8
INSTALLATION …………………………………………………………………5- 8
COOLING FAN THERMO-SWITCH ……………………………………………..5- 9
REMOVAL …………………………………………………………………………5- 9
INSPECTION ……………………………………………………………………..5- 9
INSTALLATION …………………………………………………………………5- 9
ENGINE COOLANT TEMPERATURE SENSOR ……………………………5-10
REMOVAL …………………………………………………………………………5-10
INSPECTION ……………………………………………………………………..5-10
INSTALATION ……………………………………………………………………5-10
THERMOSTAT ………………………………………………………………………….5-11
REMOVAL …………………………………………………………………………5-11
INSPECTION ……………………………………………………………………..5-11
INSTALLATION …………………………………………………………………5-12
WATER PUMP …………………………………………………………………………..5-13
REMOVAL AND DISASSEMBLY …………………………………………5-13
INSPECTION ……………………………………………………………………..5-15
REASSEMBLY AND INSTALLATION …………………………………..5-15
LUBRICATION SYSTEM …………………………………………………………….5-18
OIL PRESSURE …………………………………………………………………5-18
OIL FILTER ……………………………………………………………………….5-18
OIL PRESSURE REGULATOR ……………………………………………5-18
OIL STRAINER ………………………………………………………………….5-18
OIL JET …………………………………………………………………………….5-18
OIL PUMP …………………………………………………………………………5-18
OIL PRESSURE SWITCH ……………………………………………………5-18
OIL COOLER …………………………………………………………………………….5-18
REMOVAL …………………………………………………………………………5-18
INSPECTION AND CLEANING ……………………………………………5-19
INSTALLATION …………………………………………………………………5-19
ENGINE LUBRICATION FLOW CHART ………………………………………5-20
ENGINE LUBRICATION CIRCUIT ……………………………………………….5-21

EXTERIOR PARTS ……………………………………………………………………………………………………………………..6- 2
CONSTRUCTION …………………………………………………………………………………………………………….6- 2
REMOVAL ………………………………………………………………………………………………………………………6- 4
FRONT WHEEL ………………………………………………………………………………………………………………………….6- 8
CONSTRUCTION …………………………………………………………………………………………………………….6- 8
REMOVAL ………………………………………………………………………………………………………………………6- 9
INSPECTION AND DISASSEMBLY …………………………………………………………………………………..6- 9
REASSEMBLY AND REMOUNTING …………………………………………………………………………………6-11
FRONT FORK …………………………………………………………………………………………………………………………….6-14
CONSTRUCTION …………………………………………………………………………………………………………….6-14
REMOVAL AND DISASSEMBLY ………………………………………………………………………………………6-15
INSPECTION …………………………………………………………………………………………………………………..6-18
REASSEMBLY AND REMOUNTING …………………………………………………………………………………6-19
STEERING AND HANDLEBAR ……………………………………………………………………………………………………6-24
CONSTRUCTION …………………………………………………………………………………………………………….6-24
REMOVAL ………………………………………………………………………………………………………………………6-25
INSPECTION AND DISASSEMBLY …………………………………………………………………………………..6-28
REASSEMBLY AND REMOUNTING …………………………………………………………………………………6-29
STEERING TENSION ADJUSTMENT ………………………………………………………………………………..6-32
REAR WHEEL ……………………………………………………………………………………………………………………………6-33
CONSTRUCTION …………………………………………………………………………………………………………….6-33
REMOVAL ………………………………………………………………………………………………………………………6-34
INSPECTION AND DISASSEMBLY …………………………………………………………………………………..6-35
REASSEMBLY AND REMOUNTING …………………………………………………………………………………6-38
REAR SHOCK ABSORBER ………………………………………………………………………………………………………..6-42
CONSTRUCTION …………………………………………………………………………………………………………….6-42
REMOVAL ………………………………………………………………………………………………………………………6-43
INSPECTION …………………………………………………………………………………………………………………..6-44
REAR SHOCK ABSORBER DISPOSAL …………………………………………………………………………….6-44
REMOUNTING ………………………………………………………………………………………………………………..6-45
SUSPENSION SETTING …………………………………………………………………………………………………..6-46
REAR SWINGARM ……………………………………………………………………………………………………………………..6-47
CONSTRUCTION …………………………………………………………………………………………………………….6-47
REMOVAL ………………………………………………………………………………………………………………………6-48
INSPECTION AND DISASSEMBLY …………………………………………………………………………………..6-49
REASSEMBLY ………………………………………………………………………………………………………………..6-52
REMOUNTING ………………………………………………………………………………………………………………..6-54
FINAL INSPECTION AND ADJUSTMENT ………………………………………………………………………….6-55
FRONT BRAKE ………………………………………………………………………………………………………………………….6-56
CONSTRUCTION …………………………………………………………………………………………………………….6-56
BRAKE PAD REPLACEMENT ………………………………………………………………………………………….6-57
BRAKE FLUID REPLACEMENT ……………………………………………………………………………………….6-58
CALIPER REMOVAL AND DISASSEMBLY ……………………………………………………………………….6-59
CALIPER INSPECTION ……………………………………………………………………………………………………6-60
CALIPER REASSEMBLY AND REMOUNTING …………………………………………………………………..6-61
BRAKE DISC INSPECTION ……………………………………………………………………………………………..6-62
MASTER CYLINDER REMOVAL AND DISASSEMBLY ………………………………………………………6-63
MASTER CYLINDER INSPECTION …………………………………………………………………………………..6-64
MASTER CYLINDER REASSEMBLY AND REMOUNTING ………………………………………………….6-64
REAR BRAKE ……………………………………………………………………………………………………………………………6-66
CONSTRUCTION …………………………………………………………………………………………………………….6-66
BRAKE PAD REPLACEMENT ………………………………………………………………………………………….6-67
BRAKE FLUID REPLACEMENT ……………………………………………………………………………………….6-68
CALIPER REMOVAL AND DISASSEMBLY ……………………………………………………………………….6-69
CALIPER INSPECTION ……………………………………………………………………………………………………6-70
BRAKE DISC INSPECTION ……………………………………………………………………………………………..6-71
CALIPER REASSEMBLY AND REMOUNTING …………………………………………………………………..6-72
MASTER CYLINDER REMOVAL AND DISASSEMBLY ………………………………………………………6-73
MASTER CYLINDER INSPECTION …………………………………………………………………………………..6-74
MASTER CYLINDER REASSEMBLY AND REMOUNTING ………………………………………………….6-75
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER ……………………………………………………………6-77
CONSTRUCTION …………………………………………………………………………………………………………….6-77
CLUTCH FLUID REPLACEMENT ……………………………………………………………………………………..6-78
CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY ……………………………………….6-78
CLUTCH RELEASE CYLINDER INSPECTION ……………………………………………………………………6-79
CLUTCH RELEASE CYLINDER REASSEMBLY AND REMOUNTING ………………………………….6-79
CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY …………………………………………6-81
CLUTCH MASTER CYLINDER INSPECTION …………………………………………………………………….6-82
CLUTCH MASTER CYLINDER REASSEMBLY AND REMOUNTING ……………………………………6-82
TIRE AND WHEEL ……………………………………………………………………………………………………………………..6-84
TIRE REMOVAL ………………………………………………………………………………………………………………6-84
INSPECTION …………………………………………………………………………………………………………………..6-84
VALVE INSTALLATION …………………………………………………………………………………………………..6-85
TIRE INSTALLATION ………………………………………………………………………………………………………6-85

CAUTIONS IN SERVICING ……………………………………………………….7- 2
CONNECTOR …………………………………………………………………….7- 2
COUPLER …………………………………………………………………………7- 2
CLAMP ……………………………………………………………………………..7- 2
FUSE ………………………………………………………………………………..7- 2
SEMI-CONDUCTOR EQUIPPED PART ………………………………..7- 2
BATTERY ………………………………………………………………………….7- 3
CONNECTING THE BATTERY ……………………………………………7- 3
WIRING PROCEDURE ……………………………………………………….7- 3
USING THE MULTI CIRCUIT TESTER …………………………………7- 3
LOCATION OF ELECTRICAL COMPONENTS ……………………………7- 4
CHARGING SYSTEM ……………………………………………………………….7- 6
TROUBLESHOOTING ………………………………………………………..7- 6
INSPECTION ……………………………………………………………………..7- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM ………………………………………………………………………………….7-10
TROUBLE SHOOTING ……………………………………………………….7-10
STARTER MOTOR REMOVAL AND DISASSEMBLY …………….7-11
STARTER MOTOR INSPECTION ………………………………………..7-12
STARTER MOTOR REASSEMBLY ……………………………………..7-12
STARTER RELAY INSPECTION ………………………………………….7-13
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ……………………………………………………………………..7-14
IGNITION SYSTEM …………………………………………………………………..7-17
TROUBLESHOOTING ………………………………………………………..7-17
INSPECTION ……………………………………………………………………..7-19
COMBINATION METER ……………………………………………………………7-22
REMOVAL AND DISASSEMBLY …………………………………………7-22
INSPECTION ……………………………………………………………………..7-23
ENGINE COOLANT TEMPERATURE METER AND
INDICATOR ……………………………………………………………………….7-25
LAMPS ……………………………………………………………………………………7-29
HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN
SIGNAL LIGHT ………………………………………………………………….7-29
RELAYS ………………………………………………………………………………….7-30
TURN SIGNAL/SIDE-STAND RELAY …………………………………..7-30
STARTER RELAY ………………………………………………………………7-30
FUEL PUMP RELAY …………………………………………………………..7-30
SWITCHES ………………………………………………………………………..7-31
BATTERY ………………………………………………………………………………..7-33
SPECIFICATIONS ………………………………………………………………7-33
INITIAL CHARGING ……………………………………………………………7-33
SERVICING ……………………………………………………………………….7-35
RECHARGING OPERATION ……………………………………………….7-35

TROUBLESHOOTING ………………………………………………………………8- 2
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE
CONDITION ……………………………………………………………………….8- 2
ENGINE …………………………………………………………………………….8- 4
RADIATOR (COOLING SYSTEM) ………………………………………..8- 9
CHASSIS …………………………………………………………………………..8-10
BRAKES ……………………………………………………………………………8-11
ELECTRICAL …………………………………………………………………….8-12
BATTERY ………………………………………………………………………….8-13
WIRE HARNESS, CABLE AND HOSE ROUTING ………………………..8-14
WIRE HARNESS ROUTING ………………………………………………..8-14
ENGINE ELECTRICAL PARTS SET-UP ……………………………….8-17
HIGH-TENSION CORD ROUTING ……………………………………….8-18
THROTTLE CABLE ROUTING …………………………………………….8-19
THROTTLE BODY INSTALLATION/HOSE ROUTING ……………8-20
CRANKCASE BREATHER HOSE ROUTING ………………………..8-21
CLUTCH HOSE ROUTING ………………………………………………….8-22
COOLING SYSTEM HOSE ROUTING ………………………………….8-23
FRONT BRAKE HOSE ROUTING ………………………………………..8-24
REAR BRAKE HOSE ROUTING ………………………………………….8-25
FUEL TANK DRAIN HOSE ROUTING ………………………………….8-26
FUEL TANK INSTALLATION ………………………………………………8-27
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ……………………8-28
SEAT LOCK CABLE ROUTING …………………………………………..8-29
SIDE-STAND SET-UP …………………………………………………………8-30
BRAKE PEDAL/FOOTREST SET-UP …………………………………..8-30
FOOTREST SET-UP …………………………………………………………..8-31
HANDLEBAR BALANCER INSTALLATION …………………………8-31
SPECIAL TOOLS ……………………………………………………………………..8-32
TIGHTENING TORQUE …………………………………………………………….8-35
ENGINE …………………………………………………………………………….8-35
FI SYSTEM PARTS …………………………………………………………….8-36
CHASSIS …………………………………………………………………………..8-37
TIGHTENING TORQUE CHART …………………………………………..8-38
SERVICE DATA ……………………………………………………………………….8-39

EMISSION CONTROL SYSTEMS ………………………………………………9- 2
FUEL INJECTION SYSTEM ………………………………………………..9- 2
CRANKCASE EMISSION CONTROL SYSTEM ……………………..9- 3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ….9- 4
NOISE EMISSION CONTROL SYSTEM ……………………………….9- 5
EVAPORATIVE EMISSION CONTROL SYSTEM
(Only for E-33) …………………………………………………………………..9- 5
PAIR (AIR SUPPLY) SYSTEM INSPECTION ………………………………9- 6
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING …………………………9- 8
HEATED OXGEN SENSOR (HO2S) INSPECTION ……………………….9- 9
HEATED OXGEN SENSOR WIRE ROUTING ………………………………9-10
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33) …………………………………………………………………………9-11
CANISTER HOSE ROUTING (Only for E-33) ………………………………9-12

WIRING DIAGRAMS

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• “Clutch chudder”: A low-RPM vibration issue caused by the original clutch basket design. A common fix is to replace the clutch basket with a modified version.
• Stator magnet failure: The magnets on the stator, an electrical component, have been known to come loose on early models due to glue degradation. This can cause charging problems. If you are buying a used bike, have the stator checked.
• Voltage regulator/rectifier failure: This is a common issue with many higher-mileage bikes. Aftermarket replacements are often available for significantly less than a new Suzuki unit.
• Fueling issues: A jerky throttle response or poor running can be caused by throttle bodies that are out of sync or a dirty fuel filter. Some early DL1000s also had a low-rev “bogging” issue.
• General corrosion: While the bike is generally reliable, some riders report issues with rust and corrosion on the rear sub-frame, brake discs, and fork legs on older models.
• Ignition system: Corrosion on the front cylinder’s coil connector can lead to the bike cutting out.
• Wind buffeting: A common complaint from riders is wind buffeting from the stock windscreen, with many opting for aftermarket solutions.
• Suspension: The stock suspension is considered soft by many riders and may require replacement or rebuilding on a high-mileage bike.

• 2002–2003 (K2, K3): The first-generation models featured a 996cc, liquid-cooled V-twin engine. A major update occurred in 2003 with the addition of adjustable preload to the front forks, a stronger alternator (400W vs. 350W), and a new seat cover.
• 2004 (K4): Updates included an improved ignition system, upgraded clutch, stronger mirrors, and a redesign of the instrument panel.
• 2005 (K5): The model line added the DL1000 Grand Touring variant, which came with dealer-fitted luggage, heated grips, and a center stand.
• 2007 (K7): By this year, the engine produced around 97 horsepower.
• 2008 (K8): Minor changes were typical for this model year.
• 2009 (K9): This was the final year of this generation in many markets before the next-generation V-Strom was released. The core design remained largely unchanged from earlier models in this period. 

• Online marketplaces: Websites like eBay are common places to find used motorcycles and a wide variety of parts, including flywheels and clutch components.
• Specialty parts retailers: Online parts retailers like Twisted Throttle carry accessories, luggage, protection, and lighting that fit the 2002–2009 DL1000.
• Forum marketplaces: Rider forums, such as on Reddit (r/Vstrom), can be great places to find parts and advice from other DL1000 owners.