Suzuki TL1000S TL1000R Workshop Repair Service Manual 1998-2002 TL1000SV TL1000SW TL1000SX TL1000SY TL1000SK1 PDF - MSZKTL9802OPEK.zip
A full workshop service and repair manual for the Suzuki TL1000S and TL1000R motorcycle, complete with Electrical Wiring Diagrams, providing every technical detail needed to maintain, troubleshoot, fix, and rebuild the bike at a professional mechanic's level.
The Suzuki TL1000S, TL1000R workshop service repair manual contains:
* 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.
Suzuki TL1000RW Service Manual 1998-2002.pdf
Suzuki TL1000S (TL1000SV, TL1000SW, TL1000SX, TL1000SY, TL1000SK1) Service Manual '97-'01.pdf
Suzuki TL1000SV Service Manual '97.pdf
PRODUCT DETAILS:
Total Pages: 1,673 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Suzuki TL1000RW Service Manual 1998-2002...2
Cover...2
Index...3
1- General Info...9
2- Periodic Maintanance...19
3- Engine...47
4- Fuel Injection System...236
5- Cooling System...317
6- Chassis...335
7- Electrical System...413
8- Servicing Info...453
9- Emission Control...505
Suzuki TL1000S (TL1000SV, TL1000SW, TL1000SX, TL1000SY, TL1000SK1) Service Manual '97-'01...513
General Information...520
Warning/Caution/Note...521
General Precautions...521
Suzuki TL1000SV '97...523
Serial Number Location...523
Fuel, Oil and Engine Coolant Recommendation...523
Fuel...523
Engne Oil...524
Brake Fluid...524
Front Fork Oil...524
Engine Coolant...524
Water for Mixing...524
Anti-Freeze/Engine Coolant...524
Liquid Amount of Water/Engine Coolant...524
Break-In Procedures...525
Cylinder Indentification...525
Information Labels...526
Specifications...527
Country or Area...529
Periodic Maintenance...530
Periodic Maintenance Schedule...531
Periodic Maintenance Chart...531
Lubrication Points...532
Maintenance and Tune-Up Procedures...533
Air Cleaner...533
Spark Plug...534
Tappet Clearance...536
Tappet Clearance Adjustment...538
Intake Tappet Chart...539
Exhaust Tappet Chart...540
Fuel Hose...541
Engine Oil and Oil Filter...541
Engine Idle Speed...542
Throttle Cable Play...543
Throttle Valve Synchronisation...543
Clutch...544
Cooling System...544
Drive Chain...546
Brake...548
Tyre...551
Steering...551
Front Fork...552
Rear Suspension...552
Exhaust Pipe Bolts...552
Chassis Bolts and Nuts...553
Compression Pressure Check...555
Oil Pressure Check...556
Engine...557
Engine Components Removable with Engine in Place...558
Engine Removal and Installation...559
Engine Removal...559
Engine Installation...568
Engine Disassembly and Reassembly...575
Engine Disassembly...575
Engine Reassembly...595
Camshaft/Cylinder Head...636
Cam Drive System Description...638
Camshaft Removal...643
Cylinder Head Removal...645
Camshaft/Cylinder Head Inspection and Service...652
Cylinder Head Installation...664
Camshaft Installation...671
Cylinder/Piston...674
Cylinder/Piston Removal...675
Cylinder/Piston Inspection...677
Piston/Cylinder Installation...680
Clutch...683
Clutch Removal...684
Clutch Release Removal...685
Clutch/Clutch Release Inspection...686
Clutch Installation...688
Clutch Release Installation...691
Water Pump/Clutch Cover...692
Water Pump/Clutch Cover Removal...693
Water Pump/Clutch Cover Inspection and Service...694
Water Pump/Clutch Cover Installation...696
Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket...698
Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket Removal...699
No. 1 Cam Drive Idle Gear/Sprocket and No. Cam Drive Idle Gear Shaft/Sprocket Inspection...701
Primary Drive Gear Inspection and Service...701
Primary Drive Gear/No. 1 Cam Drive Idle Gear Shaft/Sprocket Installation...702
Starter System/Generator/Crankshaft Position Sensor...703
Starter Torque Limiter/Generator/Crankshaft Position Sensor Removal...704
Starter Torque Limiter/Generator/Crankshaft Position Sensor Inspection and Service...706
Starter Torque Limiter/Generator/Crankshaft Position Sensor Installation...709
Starter Motor Removal...711
Starter Motor Inspection and Service...711
Starter Motor Installation...711
Gearshft Linkage...712
Gearshift Linkage Removal...713
Gearshift Linkage Inspection and Service...715
Gearshift Linkage Installation...717
CrankcaseTransmission/Crankshaft/Conrod...720
Transmission/Crankshaft/Conrod Removal...722
Transmission Inspection and Removal...722
Conrod/Crankshaft Inspection...729
Conrod-Crank Pin Bearing Inspection and Service...729
Crankcase-Crankshaft Bearing Inspection and Service...732
Crankshaft Thrust Clearance Adjustment...736
Transmission/Crankshaft/Conrod Installation...737
Engine Lubrication System...738
Oil Pump...739
Oil Sum Filter/Oil Pressure Regulator...741
Oil Filter...746
Oil Pressure...746
Piston Cooling Oil Nozzle/Oil Jet...746
Engine Lubrication System Chart...747
Engine Lubrication System...748
FI System and Intake Air System...749
Precautions in Servicing...751
FI System Technical Features...757
Injection Time...757
Compensation of Injection Time...758
Injection Stop Control...758
Fuel Delivery System...759
Fuel Pump...760
Fuel Pressure Regulator...761
Fuel Injector...761
Fuel Pump Control System...762
ECM (FI Control Unit)...763
Injection Timing...764
Sensors...765
Intake Air System Technical Features...769
Intake Air Control Valve...770
Operation...771
FI System Parts Location...774
FI System Diagram...775
FI System Wiring Diagram...776
Self-Diagnosis Function...777
User Mode...777
Dealer Mode...778
Fail-Safe Function...780
FI System Troubleshooting...781
Customer Complaint Analysis...781
Self-Diagnosis Function...782
Self-Diagnosis Reset Procedure...782
Malfunction Code and Defective Condition...783
"C11" CMP Sensor Circuit Malfunction...785
"C12" CKP Sensor Circuit Malfunction...786
"C13" IAP Sensor Circuit Malfunction...787
"C14" TP Sensor Circuit Malfunction...789
"C15" ECT Sensor Circuit Malfunction...791
"C21" IAT Sensor Circuit Malfunction...792
"C22" AP Sensor Circuit Malfunction...793
"C23" TO Sensor Circuit Malfunction...795
"C24" or "C25" Ignition System Malfunction...796
"C31" Gear Position Switch Circuit Malfunction...796
"C32" or "C33" Fuel Injection Malfunction...797
"C41" FP Relay Circuit Malfunction...798
"C42" IG Switch Circuit Malfunction...798
Fuel System...799
Fuel Tank Lift-Up...799
Fuel Tank Removal...799
Fuel Pressure Inspection...800
Fuel Pump Inspection...801
Fuel Pump Relay Inspection...801
Fuel Pump and Fuel Filter Removal...801
Fuel Mesh Filter Inspection and Cleaning...802
Fuel Pump and Fuel Filter Installation...802
Throttle Body...803
Construction...803
Throttle Body Removal...804
Throttle Body Disassembly...807
Throttle Body Cleaning...810
Throttle Body Inspection...810
Throttle Body Reassembly...811
Throttle Body Installation...815
Fuel Injector Inspection...819
Fuel Injector Removal...819
Fuel Injector Installation...819
Air Screw Adjustment...819
Fast Idle Adjustment...820
Throttle Valve Synchronisation...821
Throttle Lever Gap Adjustment...824
Throttle Position Sensor Setting...824
Throttle Cable Adjustment...825
Fast Idle Cable Adjustment...825
Intake Air System...826
Intake Air System Inspection...826
VCSV Inspection...826
VTV Inspection...826
Intake Air Control Valve Actuator Inspection...827
Vacuum Damper Inspection...827
Sensors...828
IAP Sensor Inspection...828
IAP Sensor Removal/Installation...828
TP Sensor Inspection...828
TP Sensor Removal/Installation...828
CKP Sensor Inspection...828
CKP Sensor Removal/Installation...828
CMP Sensor Inspection...828
CMP Sensor Removal/Installation...828
IAT Sensor Inspection...829
IAT Sensor Removal/Installation...829
ECT Sensor Inspection...829
ECT Sensor Removal/Installation...829
AP Sensor Inspection...829
AP Sensor Removal/Installation...829
TO Sensor Inspection...829
TO Sensor Removal/Installation...829
Cooling System...830
Cooling System...831
Description...831
Construction...832
Engine Coolant...833
Radiator and Water Hoses...834
Removal...834
Inspection...835
Remounting...836
Cooling Fan...837
Removal...837
Inspection...837
Remounting...837
Cooling Fan Thermo-Switch...838
Removal...838
Inspection...839
Installation...839
Engine Coolant Temperature Sensor...840
Removal...840
Inspection...840
Installation...841
Thermostat...841
Removal...841
Inspection...842
Installation...842
Water Pump...842
Chassis...843
Exterior Parts...844
Construction...844
Removal...844
Remounting...847
Front Wheel...848
Construction...848
Removal...850
Inspection and Disassembly...850
Reassembly and Remounting...852
Front Fork...854
Construction...854
Removal and Disassembly...855
Inspection...857
Reassembly and Remounting...858
Suspension Setting...862
Steering...863
Construction...863
Removal and Disassembly...863
Inspection and Disassembly...866
Reassembly and Remounting...867
Steering Tension Adjustment...869
Rear Wheel...870
Construction...870
Removal...872
Inspection and Disassembly...873
Reassembly and Remounting...874
Rear Suspension...876
Description...876
Rotary Damper and Spring Unit Removal...880
Rotary Damper and Spring Unit Inspection and Disassembly...882
Rotary Damper and Spring Unit Reassembly and Remounting...883
Suspension Setting...885
Rear Swingarm Removal...886
Rear Swingarm Inspection and Disassembly...888
Rear Swingarm Reassembly and Remounting...889
Final Inspection and Adjustment...890
Front Brake...891
Construction...891
Brake Pad Replacement...892
Brake Fluid Replacement...892
Caliper Removal and Disassembly...893
Caliper Inspection...894