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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