Suzuki DL650 DL1000 V-Strom Workshop Repair Service Manual PDF DL650K4 DL1000K2 2002 2004 - MSZKDLOPMS.zip

This is a complete service and repair manual featuring Electrical Wiring Diagrams for the Suzuki DL650 and DL1000 motorcycles, packed with every technical detail needed to service, troubleshoot, fix, and rebuild these bikes the way professional technicians do.

Inside the Suzuki DL650, DL1000 workshop service repair manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

“99500-36130-01E.pdf”

Suzuki DL650K4 V-strom 2004 Service Manual (English); 464 pages

“99500-36130-03E.pdf”

Suzuki DL650K4 V-strom 2004 Service Manual (English); 467 pages

“DL650K4 V-strom '04 (ES).pdf”

Suzuki DL650K4 V-strom 2004 Service Manual (Spanish); 467 pages

“99500-39230-03E.pdf”

Suzuki DL1000K2 V-strom 2002 Service Manual; 450 pages; 99500-39230-03E

“99500-39230-01E.pdf”

Suzuki DL1000K2 V-strom 2002 Service Manual; 444 pages; 99500-39230-01E

PRODUCT DETAILS:

Total Pages: 2,422 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

99500-36130-01E...2

99500-36130-01E DL650K4 SERVICE MANUAL...2

FORWORD_GROUP INDEX...3

HOW TO USE THIS MANUAL...4

TO LOCATE WHAT YOU ARE LOOKING FOR:...4

COMPONENT PARTS AND WORK TO BE DONE...4

SYMBOL...5

ABBREVIATIONS USED IN THIS MANUAL...6

01. GENERAL INFORMATION...9

WARNING/CAUTION/NOTE...10

GENERAL PRECAUTIONS...10

SUZUKI DL650K4 (’04-MODEL)...12

SERIAL NUMBER LOCATION...12

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...12

BREAK-IN PROCEDURES...14

CYLINDER IDENTIFICATION...15

INFORMATION LABELS...16

SPECIFICATIONS...17

COUNTRY AND AREA CODES...19

02. PERIODIC MAINTENANCE...20

PERIODIC MAINTENANCE SCHEDULE...21

MAINTENANCE AND TUNE-UP PROCEDURES...23

COMPRESSION PRESSURE CHECK...48

OIL PRESSURE CHECK...49

03. ENGINE...50

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...51

ENGINE REMOVAL AND INSTALLATION...52

ENGINE DISASSEMBLY...68

ENGINE COMPONENTS INSPECTION AND SERVICING...85

ENGINE REASSEMBLY...131

04. FI SYSTEM DIAGNOSIS...158

PRECAUTIONS IN SERVICING...160

FI SYSTEM TECHNICAL FEATURES...167

SELF-DIAGNOSIS FUNCTION...172

FAIL-SAFE FUNCTION...175

FI SYSTEM TROUBLESHOOTING...176

SENSORS...207

05. FUEL SYSTEM AND THROTTLE BODY...209

FUEL SYSTEM...210

FUEL SYSTEM...215

THROTTLE BODY AND STV ACTUATOR...222

06. COOLING AND LUBRICATION SYSTEM...243

ENGINE COOLANT...245

COOLING CIRCUIT...246

RADIATOR...247

RADIATOR CAP...250

WATER HOSE...250

COOLING FAN...251

COOLING FAN THERMO-SWITCH...252

ECT SENSOR...253

THERMOSTAT CASE ASSEMBLY...255

WATER PUMP...257

LUBRICATION SYSTEM...263

OIL COOLER...264

ENGINE LUBRICATION FLOW CHART...266

ENGINE LUBRICATION CIRCUIT...267

07. CHASSIS...269

EXTERIOR PARTS...271

FRONT WHEEL...278

FRONT FORK...285

STEERING AND HANDLEBAR...295

REAR WHEEL...304

REAR SHOCK ABSORBER...313

REAR SWINGARM...318

FRONT BRAKE...327

REAR BRAKE...337

TIRE AND WHEEL...348

DRIVE CHAIN...352

08. ELECTRICAL SYSTEM...356

CAUTIONS IN SERVICING...357

LOCATION OF ELECTRICAL COMPONENTS...360

CHARGING SYSTEM...362

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...367

IGNITION SYSTEM...378

COMBINATION METER...384

LAMPS...391

RELAYS...392

BATTERY...395

09. SERVICING INFORMATION...398

TROUBLESHOOTING...399

WIRE HARNESS, CABLE AND HOSE ROUTING...413

TIGHTENING TORQUE...437

SERVICE DATA...441

10. EMISSION CONTROL INFORMATION...453

EMISSION CONTROL SYSTEMS...454

PAIR (AIR SUPPLY) SYSTEM INSPECTION...458

11. WIRING DIAGRAM...462

99500-36130-03E...466

99500-39230-01E...933

DL1000K2 SERVICE MANUAL...933

FORWORD_GROUP INDEX...934

HOW TO USE THIS MANUAL...935

TO LOCATE WHAT YOU ARE LOOKING FOR:...935

COMPONENT PARTS AND WORK TO BE DONE...935

SYMBOL...936

ABBREVIATIONS USED IN THIS MANUAL...937

01. GENERAL INFORMATION...939

WARNING/CAUTION/NOTE...940

GENERAL PRECAUTIONS...940

SUZUKI DL1000K2 (’02-MODEL)...942

SERIAL NUMBER LOCATION...942

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...942

BREAK-lN PROCEDURES...944

CYLINDER IDENTIFICATION...944

INFORMATION LABELS...945

SPECIFICATIONS...946

COUNTRY AND AREA CODES...948

02. PERIODIC MAINTENANCE...949

PERIODIC MAINTENANCE SCHEDULE...950

MAINTENANCE AND TUNE-UP PROCEDURES...952

COMPRESSION PRESSURE CHECK...977

OIL PRESSURE CHECK...978

03. ENGINE...979

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...980

ENGINE REMOVAL AND INSTALLATION...981

ENGINE DISASSEMBLY...997

ENGINE COMPONENTS INSPECTION AND SERVICING...1012

ENGINE REASSEMBLY...1056

04. FI SYSTEM...1091

PRECAUTIONS IN SERVICING...1093

FI SYSTEM TECHNICAL FEATURES...1100

FI SYSTEM PARTS LOCATION...1111

FI SYSTEM WIRING DIAGRAM...1113

SELF-DIAGNOSIS FUNCTION...1114

FAIL-SAFE FUNCTION...1117

FI SYSTEM TROUBLESHOOTING...1118

FUEL SYSTEM...1142

THROTTLE BODY AND STV ACTUATOR...1150

SENSOR...1165

05. COOLING AND LUBRICATION SYSTEM...1169

ENGINE COOLANT...1170

COOLING CIRCUIT...1171

RADIATOR...1172

RADIATOR RESERVOIR TANK...1174

RADIATOR CAP...1174

WATER HOSE...1175

COOLING FAN...1176

COOLING FAN THERMO-SWITCH...1177

ENGINE COOLANT TEMPERATURE SENSOR...1178

THERMOSTAT...1179

WATER PUMP...1181

LUBRICATION SYSTEM...1186

OIL COOLER...1186

ENGINE LUBRICATION FLOW CHART...1188

ENGINE LUBRICATION CIRCUIT...1189

06. CHASSIS...1190

EXTERIOR PARTS...1191

FRONT WHEEL...1197

FRONT FORK...1203

STEERING AND HANDLEBAR...1213

REAR WHEEL...1222

REAR SHOCK ABSORBER...1231

REAR SWINGARM...1236

FRONT BRAKE...1245

REAR BRAKE...1255

CLUTCH RELEASE CYLINDER AND MASTER CYLINDER...1266

TIRE AND WHEEL...1273

07. ELECTRICAL SYSTEM...1276

CAUTIONS IN SERVICING...1277

LOCATION OF ELECTRICAL COMPONENTS...1279

CHARGING SYSTEM...1281

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...1285

IGNITION SYSTEM...1292

COMBINATION METER...1297

LAMPS...1304

RELAYS...1305

BATTERY...1308

08. SERVICING INFORMATION...1311

TROUBLESHOOTING...1312

WIRE HARNESS, CABLE AND HOSE ROUTING...1324

SPECIAL TOOLS...1342

TIGHTENING TORQUE...1345

SERVICE DATA...1349

09. EMISSION CONTROL INFORMATION...1359

EMISSION CONTROL SYSTEMS...1360

PAIR (AIR SUPPLY) SYSTEM INSPECTION...1364

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...1366

HEATED OXGEN SENSOR (HO2S) INSPECTION...1367

HEATED OXGEN SENSOR WIRE ROUTING...1368

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)...1369

CANISTER HOSE ROUTING (Only for E-33)...1370

10. WIRING DIAGRAM...1371

99500-39230-03E...1377

0 Foreword...1377

1 General Info...1387

2 Periodic Maintenance...1397

3A Engine...1429

3B Engine...1491

4 Fuel Injection...1541

5 Cooling & Lubrication...1621

6A Chassis...1643

6B Chassis...1699

7 Electrical...1729

8 Servicing...1765

9 Emission Control...1813

10A Wiring...1823

10B Wiring...1825

10C Wiring...1826

DL650K4 V-strom '04 (ES)...1827

CAP II MANTENIMIENTO PERIODICO...1844

CAP III MOTOR...1876

CAP IV DIAGNOSTICO DEL SISTEMA FI...1986

CAP V SISTEMA DE COMBUSTIBLE...2039

CAP VI SISTEMA DE REFRIGERACION Y LUBRICACION...2075

CAP VII CHASIS...2101

CAP VIII SISTEMA ELECTRICO...2189

CAP IX INFORMACION DE SERVICIO...2231

CAP X CONTROL DE EMISIONES...2283

CAP XI DIAGRAMA DE CABLEADO...2292

Parts Catalog...2294

Gasket Set...2294

Front Cylinder Head...2296

Rear Cylinder Head...2298

Cylinder...2300

Crankcase...2302

Crankcase Cover...2304

Crankshaft...2306

Sharter Clutch...2308

Cam Shaft/Valve...2310

Cam Chain...2312

Throttle Body...2314

Fuel Delivery Pipe...2316

Air Cleaner...2318

Muffler...2320

Oil Pump...2322

Fuel Pump...2324

Oil Cooler...2326

Water Pump...2328

Radiator...2330

Radiator Hose...2332

2nd Air...2334

Clutch...2336

Transmission...2338

Gear Shifting...2340

Starting Motor...2342

Magneto...2344

Battery...2346

Electrical...2348

Speedometer...2350

Head Lamp...2352

Turnsignal Lamp...2354

Tail Lamp...2356

Wiring Harness...2358

Handle Switch...2360

Frame...2362

Stand...2364

Footrest...2366

Carrier...2368

Fuel Tank...2370

Front Bracket...2372

Evapo System...2374

Frame Cover...2376

Front Fender...2378

Handle Bar...2380

Handle Lever...2382

Rear Fender...2384

Cowling Body...2386

Cowl Installation Parts...2388

Side Cowling...2390

Side Cowling Installation Parts...2392

Label...2394

Seat...2396

Seat Tail Cover...2398

Front Damper...2400

Steering Stem...2402

Front Wheel...2404

Front Caliper...2406

Front Brake Hose...2408

Front Master Cylinder...2410

Rear Swinging Arm...2412

Rear Cushion Lever...2414

Rear Wheel...2416

Rear Caliper...2418

Rear Master Cylinder...2420

Optional...2422