SUZUKI TL 1000S SERVICE MANUAL – PDF DOWNLOAD

Description

SUZUKI TL 1000S SERVICE MANUAL – PDF DOWNLOAD

DESCRIPTION:

SUZUKI TL 1000S SERVICE MANUAL – PDF DOWNLOAD

FOREWORD

This manual contains an introductory description on the SUZUKI TL 1000S and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the

GENERAL INFORMATION

section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services de• scribed in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

IMPORTANT

• All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements.
• This manual includes specific information required to properly inspect and service TL 1000S in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed.
• Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN.

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right w ill allow you to find the first page of the section easily.

4. The contents are listed on the first page of each section to help find the item and page you need.
TABLE OF CONTENTS:

SUZUKI TL 1000S SERVICE MANUAL – PDF DOWNLOAD

General Information.................................................................................  8
	Warning/Caution/Note............................................................................  9
	General Precautions.............................................................................  9
	Suzuki TL1000SV '97............................................................................. 11
	Serial Number Location.......................................................................... 11
	Fuel, Oil and Engine Coolant Recommendation..................................................... 11
		Fuel........................................................................................ 11
		Engne Oil................................................................................... 12
		Brake Fluid................................................................................. 12
		Front Fork Oil.............................................................................. 12
		Engine Coolant.............................................................................. 12
		Water for Mixing............................................................................ 12
		Anti-Freeze/Engine Coolant.................................................................. 12
		Liquid Amount of Water/Engine Coolant....................................................... 12
	Break-In Procedures............................................................................. 13
	Cylinder Indentification........................................................................ 13
	Information Labels.............................................................................. 14
	Specifications.................................................................................. 15
	Country or Area................................................................................. 17
Periodic Maintenance................................................................................ 18
	Periodic Maintenance Schedule................................................................... 19
		Periodic Maintenance Chart.................................................................. 19
		Lubrication Points.......................................................................... 20
	Maintenance and Tune-Up Procedures.............................................................. 21
		Air Cleaner................................................................................. 21
		Spark Plug.................................................................................. 22
		Tappet Clearance............................................................................ 24
			Tappet Clearance Adjustment............................................................. 26
			Intake Tappet Chart..................................................................... 27
			Exhaust Tappet Chart.................................................................... 28
		Fuel Hose................................................................................... 29
		Engine Oil and Oil Filter................................................................... 29
		Engine Idle Speed........................................................................... 30
		Throttle Cable Play......................................................................... 31
		Throttle Valve Synchronisation.............................................................. 31
		Clutch...................................................................................... 32
		Cooling System.............................................................................. 32
		Drive Chain................................................................................. 34
		Brake....................................................................................... 36
		Tyre........................................................................................ 39
		Steering.................................................................................... 39
		Front Fork.................................................................................. 40
		Rear Suspension............................................................................. 40
		Exhaust Pipe Bolts.......................................................................... 40
		Chassis Bolts and Nuts...................................................................... 41
	Compression Pressure Check...................................................................... 43
	Oil Pressure Check.............................................................................. 44
Engine.............................................................................................. 45
	Engine Components Removable with Engine in Place................................................ 46
	Engine Removal and Installation................................................................. 47
		Engine Removal.............................................................................. 47
		Engine Installation......................................................................... 56
	Engine Disassembly and Reassembly............................................................... 63
		Engine Disassembly.......................................................................... 63
		Engine Reassembly........................................................................... 83
	Camshaft/Cylinder Head..........................................................................124
		Cam Drive System Description................................................................126
		Camshaft Removal............................................................................131
		Cylinder Head Removal.......................................................................133
		Camshaft/Cylinder Head Inspection and Service...............................................140
		Cylinder Head Installation..................................................................152
		Camshaft Installation.......................................................................159
	Cylinder/Piston.................................................................................162
		Cylinder/Piston Removal.....................................................................163
		Cylinder/Piston Inspection..................................................................165
		Piston/Cylinder Installation................................................................168
	Clutch..........................................................................................171
		Clutch Removal..............................................................................172
		Clutch Release Removal......................................................................173
		Clutch/Clutch Release Inspection............................................................174
		Clutch Installation.........................................................................176
		Clutch Release Installation.................................................................179
	Water Pump/Clutch Cover.........................................................................180
		Water Pump/Clutch Cover Removal.............................................................181
		Water Pump/Clutch Cover Inspection and Service..............................................182
		Water Pump/Clutch Cover Installation........................................................184
	Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket.....................................186
		Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket Removal.........................187
		No. 1 Cam Drive Idle Gear/Sprocket and No. Cam Drive Idle Gear Shaft/Sprocket Inspection....189
		Primary Drive Gear Inspection and Service...................................................189
		Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket Installation....................190
	Starter System/Generator/Crankshaft Position Sensor.............................................191
		Starter Torque Limiter/Generator/Crankshaft Position Sensor Removal.........................192
		Starter Torque Limiter/Generator/Crankshaft Position Sensor Inspection and Service..........194
		Starter Torque Limiter/Generator/Crankshaft Position Sensor Installation....................197
		Starter Motor Removal.......................................................................199
		Starter Motor Inspection and Service........................................................199
		Starter Motor Installation..................................................................199
	Gearshft Linkage................................................................................200
		Gearshift Linkage Removal...................................................................201
		Gearshift Linkage Inspection and Service....................................................203
		Gearshift Linkage Installation..............................................................205
	CrankcaseTransmission/Crankshaft/Conrod.........................................................208
		Transmission/Crankshaft/Conrod Removal......................................................210
		Transmission Inspection and Removal.........................................................210
		Conrod/Crankshaft Inspection................................................................217
		Conrod-Crank Pin Bearing Inspection and Service.............................................217
		Crankcase-Crankshaft Bearing Inspection and Service.........................................220
		Crankshaft Thrust Clearance Adjustment......................................................224
		Transmission/Crankshaft/Conrod Installation.................................................225
	Engine Lubrication System.......................................................................226
		Oil Pump....................................................................................227
		Oil Sum Filter/Oil Pressure Regulator.......................................................229
		Oil Filter..................................................................................234
		Oil Pressure................................................................................234
		Piston Cooling Oil Nozzle/Oil Jet...........................................................234
		Engine Lubrication System Chart.............................................................235
		Engine Lubrication System...................................................................236
FI System and Intake Air System.....................................................................237
	Precautions in Servicing........................................................................239
	FI System Technical Features....................................................................245
		Injection Time..............................................................................245
		Compensation of Injection Time..............................................................246
		Injection Stop Control......................................................................246
		Fuel Delivery System........................................................................247
		Fuel Pump...................................................................................248
		Fuel Pressure Regulator.....................................................................249
		Fuel Injector...............................................................................249
		Fuel Pump Control System....................................................................250
		ECM (FI Control Unit).......................................................................251
		Injection Timing............................................................................252
		Sensors.....................................................................................253
	Intake Air System Technical Features............................................................257
		Intake Air Control Valve....................................................................258
		Operation...................................................................................259
	FI System Parts Location........................................................................262
	FI System Diagram...............................................................................263
	FI System Wiring Diagram........................................................................264
	Self-Diagnosis Function.........................................................................265
		User Mode...................................................................................265
		Dealer Mode.................................................................................266
	Fail-Safe Function..............................................................................268
	FI System Troubleshooting.......................................................................269
		Customer Complaint Analysis.................................................................269
		Self-Diagnosis Function.....................................................................270
		Self-Diagnosis Reset Procedure..............................................................270
		Malfunction Code and Defective Condition....................................................271
		"C11" CMP Sensor Circuit Malfunction........................................................273
		"C12" CKP Sensor Circuit Malfunction........................................................274
		"C13" IAP Sensor Circuit Malfunction........................................................275
		"C14" TP Sensor Circuit Malfunction.........................................................277
		"C15" ECT Sensor Circuit Malfunction........................................................279
		"C21" IAT Sensor Circuit Malfunction........................................................280
		"C22" AP Sensor Circuit Malfunction.........................................................281
		"C23" TO Sensor Circuit Malfunction.........................................................283
		"C24" or "C25" Ignition System Malfunction..................................................284
		"C31" Gear Position Switch Circuit Malfunction..............................................284
		"C32" or "C33" Fuel Injection Malfunction...................................................285
		"C41" FP Relay Circuit Malfunction..........................................................286
		"C42" IG Switch Circuit Malfunction.........................................................286
	Fuel System.....................................................................................287
		Fuel Tank Lift-Up...........................................................................287
		Fuel Tank Removal...........................................................................287
		Fuel Pressure Inspection....................................................................288
		Fuel Pump Inspection........................................................................289
		Fuel Pump Relay Inspection..................................................................289
		Fuel Pump and Fuel Filter Removal...........................................................289
		Fuel Mesh Filter Inspection and Cleaning....................................................290
		Fuel Pump and Fuel Filter Installation......................................................290
	Throttle Body...................................................................................291
		Construction................................................................................291
		Throttle Body Removal.......................................................................292
		Throttle Body Disassembly...................................................................295
		Throttle Body Cleaning......................................................................298
		Throttle Body Inspection....................................................................298
		Throttle Body Reassembly....................................................................299
		Throttle Body Installation..................................................................303
		Fuel Injector Inspection....................................................................307
		Fuel Injector Removal.......................................................................307
		Fuel Injector Installation..................................................................307
		Air Screw Adjustment........................................................................307
		Fast Idle Adjustment........................................................................308
		Throttle Valve Synchronisation..............................................................309
		Throttle Lever Gap Adjustment...............................................................312
		Throttle Position Sensor Setting............................................................312
		Throttle Cable Adjustment...................................................................313
		Fast Idle Cable Adjustment..................................................................313
	Intake Air System...............................................................................314
		Intake Air System Inspection................................................................314
		VCSV Inspection.............................................................................314
		VTV Inspection..............................................................................314
		Intake Air Control Valve Actuator Inspection................................................315
		Vacuum Damper Inspection....................................................................315
	Sensors.........................................................................................316
		IAP Sensor Inspection.......................................................................316
		IAP Sensor Removal/Installation.............................................................316
		TP Sensor Inspection........................................................................316
		TP Sensor Removal/Installation..............................................................316
		CKP Sensor Inspection.......................................................................316
		CKP Sensor Removal/Installation.............................................................316
		CMP Sensor Inspection.......................................................................316
		CMP Sensor Removal/Installation.............................................................316
		IAT Sensor Inspection.......................................................................317
		IAT Sensor Removal/Installation.............................................................317
		ECT Sensor Inspection.......................................................................317
		ECT Sensor Removal/Installation.............................................................317
		AP Sensor Inspection........................................................................317
		AP Sensor Removal/Installation..............................................................317
		TO Sensor Inspection........................................................................317
		TO Sensor Removal/Installation..............................................................317
Cooling System......................................................................................318
	Cooling System..................................................................................319
		Description.................................................................................319
		Construction................................................................................320
	Engine Coolant..................................................................................321
	Radiator and Water Hoses........................................................................322
		Removal.....................................................................................322
		Inspection..................................................................................323
		Remounting..................................................................................324
	Cooling Fan.....................................................................................325
		Removal.....................................................................................325
		Inspection..................................................................................325
		Remounting..................................................................................325
	Cooling Fan Thermo-Switch.......................................................................326
		Removal.....................................................................................326
		Inspection..................................................................................327
		Installation................................................................................327
	Engine Coolant Temperature Sensor...............................................................328
		Removal.....................................................................................328
		Inspection..................................................................................328
		Installation................................................................................329
	Thermostat......................................................................................329
		Removal.....................................................................................329
		Inspection..................................................................................330
		Installation................................................................................330
	Water Pump......................................................................................330
Chassis.............................................................................................331
	Exterior Parts..................................................................................332
		Construction................................................................................332
		Removal.....................................................................................332
		Remounting..................................................................................335
	Front Wheel.....................................................................................336
		Construction................................................................................336
		Removal.....................................................................................338
		Inspection and Disassembly..................................................................338
		Reassembly and Remounting...................................................................340
	Front Fork......................................................................................342
		Construction................................................................................342
		Removal and Disassembly.....................................................................343
		Inspection..................................................................................345
		Reassembly and Remounting...................................................................346
		Suspension Setting..........................................................................350
	Steering........................................................................................351
		Construction................................................................................351
		Removal and Disassembly.....................................................................351
		Inspection and Disassembly..................................................................354
		Reassembly and Remounting...................................................................355
		Steering Tension Adjustment.................................................................357
	Rear Wheel......................................................................................358
		Construction................................................................................358
		Removal.....................................................................................360
		Inspection and Disassembly..................................................................361
		Reassembly and Remounting...................................................................362
	Rear Suspension.................................................................................364
		Description.................................................................................364
		Rotary Damper and Spring Unit Removal.......................................................368
		Rotary Damper and Spring Unit Inspection and Disassembly....................................370
		Rotary Damper and Spring Unit Reassembly and Remounting.....................................371
		Suspension Setting..........................................................................373
		Rear Swingarm Removal.......................................................................374
		Rear Swingarm Inspection and Disassembly....................................................376
		Rear Swingarm Reassembly and Remounting.....................................................377
		Final Inspection and Adjustment.............................................................378
	Front Brake.....................................................................................379
		Construction................................................................................379
		Brake Pad Replacement.......................................................................380
		Brake Fluid Replacement.....................................................................380
		Caliper Removal and Disassembly.............................................................381
		Caliper Inspection..........................................................................382
		Caliper Reassembly and Remounting...........................................................382
		Disc Servicing..............................................................................383
		Master Cylinder Removal and Disassembly.....................................................384
		Master Cylinder Inspection..................................................................385
		Master Cylinder Reassembly and Remounting...................................................385
	Rear Brake......................................................................................387
		Construction................................................................................387
		Brake Pad Replacement.......................................................................388
		Brake Fluid Replacement.....................................................................388
		Caliper Removal and Disassembly.............................................................389
		Caliper Inspection..........................................................................390
		Caliper Reassembly and Remounting...........................................................390
		Master Cylinder Removal and Disassembly.....................................................391
		Master Cylinder Inspection..................................................................392
		Master Cylinder Reassembly and Remounting...................................................392
	Tyre and Wheel..................................................................................393
		Tyre Removal................................................................................393
		Tyre Inspection.............................................................................395
		Tyre Installation...........................................................................396
Electrical System...................................................................................398
	Cautions In Servicing...........................................................................399
	Location of Electrical Components...............................................................401
	Charging System.................................................................................403
		Description.................................................................................403
		Troubleshooting.............................................................................405
		Inspection..................................................................................406
	Starter System and Side-Stand/Ignition Interlock System.........................................408
		Starter System Description..................................................................408
		Side-Stand/Ignition Interlock System Description............................................408
		Troubleshooting.............................................................................410
		Starter Motor Removal and Disassembly.......................................................411
		Starter Motor Inspection....................................................................411
		Starter Motor Reassembly....................................................................412
		Starter Relay Inspection....................................................................413
		Side-Stand/Ignition Interlock System Part Inspection........................................414
	Ignition System.................................................................................417
		Description.................................................................................417
		Troubleshooting.............................................................................419
		Inspection..................................................................................420
	Combination Meter...............................................................................424
		Removal.....................................................................................424
		Disassembly.................................................................................424
		Inspection..................................................................................425
	Lamps...........................................................................................430
		Headlight...................................................................................430
		Brake Light/Tail Light and License Light....................................................433
		Turn Signal Light...........................................................................433
	Relay...........................................................................................434
	Switches........................................................................................435
	Battery.........................................................................................436
		Specifications..............................................................................436
		Initial Charging............................................................................436
		Servicing...................................................................................437
		Recharging Operations.......................................................................438
Servicing Information...............................................................................439
	Troubleshooting.................................................................................440
		FI System Malfunction Codes and Defective Condition.........................................440
		Engine......................................................................................442
		Radiator....................................................................................447
		Chassis.....................................................................................448
		Brakes......................................................................................449
		Electrical..................................................................................450
		Battery.....................................................................................451
	Wiring Diagram..................................................................................452
		FI Wiring Diagram...........................................................................452
		Wiring Diagram..............................................................................453
	Wire Harness, Cable and Hose Routing............................................................458
		Wire Harness Routing........................................................................458
		Cable Routing...............................................................................461
		Fuel System Hose Routing....................................................................463
		Cooling System Hose Routing.................................................................465
		Front Brake Hose Routing....................................................................466
		Rear Brake Hose Routing.....................................................................467
	Fairing Cushion.................................................................................469
	Special Tools...................................................................................470
	Tightening Torque...............................................................................473
	Service Data....................................................................................476
Emission Control Information........................................................................485
	Fuel Injection System...........................................................................486
	Evaporative Emission Control System.............................................................486
	Canister Hose Routing...........................................................................487
	Evaporative Emission Control System Inspection..................................................487
Later Model Information.............................................................................488
	TL1000SW '98....................................................................................488
		General Information.........................................................................489
			Information Labels......................................................................490
			Specifications..........................................................................491
		Periodic Maintenance........................................................................493
			Maintenance and Tune-Up Procedures......................................................494
				Spark Plug..........................................................................494
		Engine......................................................................................495
		FI System and Intake Air System.............................................................499
		Cooling System..............................................................................503
		Chassis.....................................................................................508
		Service Information.........................................................................518
		Emission Control Information................................................................527
	TL1000SX '99....................................................................................531
		General Information.........................................................................532
		Engine......................................................................................535
		Service Information.........................................................................544
	TL1000SY '00....................................................................................554
		General Information.........................................................................555
			Specifications..........................................................................556
		Engine......................................................................................558
		Servicing Information.......................................................................561
	TL1000SK1 '01...................................................................................572
		Specification...............................................................................573
		Service Data................................................................................574
		Clutch......................................................................................583
		Front Brake Hose Routing....................................................................584
		Crankcase Breather..........................................................................585
Microfiche..........................................................................................586

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