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

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

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Suzuki. Read and print pages, or copy the entire manual to your hard drive.

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.