![Kawasaki KLV1000 (2004) [319/529] Inspection](/img/pdf.png)
Kawasaki KLV1000 (2004) [319/529] Inspection
![Kawasaki KLV1000 (2004) [319/529] Inspection](/views2/1121213/page319/bg13f.png)
6-18 CHASSIS
INSPECTION
INNER AND OUTER TUBES
Inspect the inner tube outer surface and the outer tube inner sur-
face for scratches. If any defects are found, replace them with
the new ones.
FORK SPRING
Measure the fork spring free length. If it is shorter than the ser-
vice limit, replace it with a new one.
Front fork spring free length
Service limit: 442.0 mm (17.40 in)
DAMPER ROD
Move the inner rod by hand to examine it for smoothness. If any
defects are found, replace the inner/damper rod (cartridge).
Содержание
- Klv1000 p.1
- Kawasaki heavy industries ltd first edition 1 feb 12 2004 k p.2
- Motorcycle service manual supplement p.2
- Klv1000 p.2
- Warning p.4
- How to use this manual p.4
- Foreword p.4
- Caution p.4
- Symbol p.5
- General information 1 1 p.8
- General information p.8
- Contents p.8
- General information 1 2 p.9
- General precautions p.9
- Kawasaki lv1000 a1 p.10
- Specifications p.11
- General information 1 4 p.11
- General information 1 5 p.12
- General information 1 6 p.13
- Country and area codes p.13
- Periodic maintenance 2 1 p.14
- Periodic maintenance p.14
- Contents p.14
- The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy maintenance intervals are expressed in terms of hours p.15
- Periodic maintenance schedule p.15
- Periodic maintenance chart p.15
- Periodic maintenance 2 2 p.15
- Note more frequent servicing may be performed on motorcycles that are use under severe conditions p.15
- I inspect and clean adjust replace or lubricate as necessary r replace t tighten c clean p.15
- Valve clearance adjustment chart inlet valve p.16
- Periodic maintenance 2 3 p.16
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in horizontal column 4 install the shim specified where the lines intersect this shim will give the proper clearance example present shim is 2 0 mm measured clearance is 0 3 mm replace 2 0 mm shim with 2 0 mm shim 5 remeasure the valve clearance and readjust if necessary p.16
- Valve clearance adjustment chart exhaust valve p.17
- Periodic maintenance 2 4 p.17
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in horizontal column 4 install the shim specified where the lines intersect this shim will give the proper clearance example present shim is 2 0 mm measured clearance is 0 8 mm replace 2 0 mm shim with 3 5 mm shim 5 remeasure the valve clearance and readjust if necessary p.17
- Exhaust p.17
- Engine 3 1 p.18
- Engine p.18
- Contents p.18
- Fi system 4 1 p.20
- Fi system p.20
- Contents p.20
- Fi system 4 2 p.21
- Cooling system p.22
- Contents p.22
- Cooling system 5 1 p.22
- Cooling system 5 2 p.23
- Contents p.24
- Chassis p.24
- Electrical system 7 1 p.26
- Electrical system p.26
- Contents p.26
- Servicing information 8 1 p.28
- Servicing information p.28
- Contents p.28
- Special tools p.29
- Servicing information 8 2 p.29
- Servicing information 8 3 p.30
- Servicing information 8 4 p.31
- Servicing information 8 5 p.32
- Servicing information 8 6 p.33
- Servicing information 8 7 p.34
- Servicing information 8 8 p.35
- Servicing information 8 9 p.36
- Emission control information 9 1 p.38
- Emission control information p.38
- Contents p.38
- Suzuki dl1000 p.40
- Base manual p.40
- Fi system p.42
- Engine p.42
- Emission control information p.42
- Electrical system p.42
- Dl1000k4 04 model p.42
- Dl1000k3 03 model p.42
- Cooling and lubrication system p.42
- Chassis p.42
- Wiring diagram p.42
- Servicing information p.42
- Periodic maintenance p.42
- Group index p.42
- General information p.42
- Foreword p.42
- Under the name of each system or unit is its exploded view work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided p.43
- To locate what you are looking for p.43
- 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 will 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 you find the item and page you need p.43
- Item n m kgf m lb ft p.43
- How to use this manual p.43
- Example front wheel p.43
- Component parts and work to be done p.43
- 23 2 16 p.43
- 100 10 72 p.43
- 32110 use special tool p.44
- Use fork oil p.44
- Symbol p.44
- Apply thread lock super 1303 99000 32030 measure in continuity test range p.44
- Apply suzuki moly paste 99000 25140 measure in voltage range p.44
- Apply suzuki bond 1215 99000 31110 measure in diode test range p.44
- Apply suzuki bond 1207b 99000 31140 measure in current range p.44
- Apply or use brake fluid p.44
- Abbreviations used in this manual p.45
- General information p.48
- Warning caution note p.49
- General precautions p.49
- Serial number location p.51
- Right side left side p.51
- Fuel oil and engine coolant recommendation p.51
- Fuel for other countries p.51
- Fuel for canadian model p.51
- Suzuki dl1000k2 02 model p.51
- Water for mixing p.52
- Liquid amount of water engine coolant p.52
- Front fork oil p.52
- Engine oil p.52
- Engine coolant p.52
- Brake fluid p.52
- Anti freeze engine coolant p.52
- Cylinder identification p.53
- Break ln procedures p.53
- Information labels p.54
- General information 1 7 p.54
- Specifications p.55
- Engine p.55
- Drive train p.55
- Dimensions and dry mass p.55
- Electrical p.56
- Chassis p.56
- Capacities p.56
- Country and area codes p.57
- Periodic maintenance p.58
- Periodic maintenance schedule p.59
- Periodic maintenance chart p.59
- Proper lubrication is important for smooth operation and long life of each working part of the motorcycle major lubrication points are indicated below p.60
- Periodic maintenance 2 3 p.60
- Note before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions p.60
- Lubrication points p.60
- Maintenance and tune up pro cedures p.61
- Air cleaner p.61
- Spark plug p.62
- Tappet clearance p.64
- Intake side p.67
- Exhaust side p.68
- Fuel hose p.69
- Engine oil and oil filter p.69
- Throttle cable play p.71
- Engine idle speed p.71
- Throttle valve synchronization p.72
- Pair air supply system p.72
- Clutch p.73
- Cooling system p.74
- Drive chain p.76
- Steering p.82
- Rear suspension p.83
- Front fork p.83
- Exhaust pipe bolt p.83
- Chassis bolt and nut p.84
- 1 400 kpa 10 14 kgf c p.86
- Kpa 8 kgf c p.86
- Kpa 2 kgf c p.86
- Compression test procedure p.86
- Compression pressure check p.86
- 199 psi p.86
- Oil pressure test procedure p.87
- Oil pressure check p.87
- Engine p.88
- Engine components removable with engine in place p.89
- Engine removal and installation p.90
- Engine removal p.90
- Remount the engine in the reverse order of engine removal pay attention to the following points p.99
- Note the engine mounting nuts are self locking once the nut has been removed it is no longer of any use be sure to use new nuts and then tighten them to the specified torque p.99
- Engine installation p.99
- 12 engine p.99
- Engine disassembly p.106
- Engine top side p.106
- Engine bottom side p.112
- Engine components inspection and servicing p.121
- Cylinder head cover p.121
- Camshaft cylinder head p.122
- Cylinder piston inspection p.134
- Using a micrometer measure the piston outside diameter at 10 mm 0 in from the piston skirt end if the measurement is less than the limit replace the piston p.135
- Conrod crankshaft p.137
- Clutch p.141
- Transmission p.143
- Construction p.143
- 56 engine p.143
- Gearshift fork p.149
- Primary drive gear p.150
- Starter torque limiter p.151
- Starter clutch p.152
- Gearshift p.153
- Crankcase p.153
- Crankcase crankshaft bearing p.158
- Generator cover p.164
- Gearshift cover p.164
- Clutch cover p.164
- Engine reassembly p.165
- Engine bottom side p.165
- Use the new gasket to prevent oil leakage p.176
- Note the no driven plate should be installed between 4th to 7th position from the clutch sleeve hub set the numbers of driven plate to the standard specifications when replacing the driven plates with the new ones p.176
- Engine 3 89 p.176
- Driven plate no driven plate 8 pcs standard 7pcs no driven plate 4 pcs standard 2pcs p.176
- Drive plate no drive plate pcs no drive plate pc no drive plate pc p.176
- Clutch cover install the gasket and dowel pins p.176
- Engine top side p.179
- No 1 front cylinder tdc of compression stroke p.192
- No front cylinder head p.194
- No rear cylinder head p.196
- No 1 front cylinder tdc of compression stroke p.197
- Fi system p.201
- Contents p.201
- Precautions in servicing p.203
- Connector coupler p.203
- Ecm various sensors p.204
- Electrical circuit inspection procedure p.206
- Using testers p.209
- Injection time injection volume p.210
- Fi system technical features p.210
- Injection stop control p.211
- Compensation of injection time volume p.211
- Fi system 4 11 p.212
- 43 psi the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ecm the fuel relieved by the fuel pressure regulator flows back to the fuel tank p.212
- The fuel delivery system consists of the fuel tank fuel pump fuel filters fuel feed hose fuel delivery pipe including fuel injectors and fuel pressure regulator there is no fuel return hose the fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe fuel pressure is regulated by the fuel pressure regulator as the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kpa 3 kgf c p.212
- Fuel delivery system p.212
- When the impeller is driven by the motor pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction this process continuously takes place causing fuel pressure to be built up the pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve p.213
- The electric fuel pump is mounted at the bottom of the fuel tank which consists of the armature magnet impeller brush check valve and relief valve the ecm controls its on off operation as controlled under the fuel pump control system when electrical energy is supplied to the fuel pump the motor in the pump runs and together with the impel ler this causes a pressure difference to occur on both sides of the impeller as there are many grooves around it then the fuel is drawn through the inlet port and with its pressure increased it is discharged through the outlet port the fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped also the relief valve is equipped in the fuel pump which releases pressur ized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 600 kpa 4 6 kgf c p.213
- Fuel pump p.213
- 64 85 psi p.213
- 12 fi system p.213
- Fuel pressure regulator p.214
- Fuel injector p.214
- When the ignition switch is turned on current from the battery flows to the fuel pump motor through the side stand relay and the fuel pump relay causing the motor to turn since the ecm has a timer function the fuel pump motor stops turning in three seconds after the switch has been turned on thereafter when the crankshaft is turned by the starter motor or the engine has been started the engine revolving signal is input to the ecm then current flows to the fuel pump motor from the battery through the side stand relay and the fuel pump relay so that the pump continues to function a tip over sensor is provided in the fuel pump control circuit by this provision anytime the motorcycle tips over the tip over sensor sends a signal to the ecm to turn off power to the fuel pump relay causing the fuel pump motor to stop at the same time current to the fuel injectors as well as the ignition coil is interrupted which then stops the engine p.215
- Fuel pump control system p.215
- 14 fi system p.215
- Injection timing p.216
- Ecm fi control unit p.216
- Sensors p.217
- 20 fi system p.221
- Fi system parts location p.221
- Fi system 4 21 p.222
- Fi system wiring diagram p.223
- 22 fi system p.223
- User mode p.224
- Self diagnosis function p.224
- Dealer mode p.225
- Tps adjustment p.226
- Position correcte p.226
- Incorrect p.226
- Fail safe function p.227
- Fi system troubleshooting p.228
- Customer complaint analysis p.228
- Motorcycle environmental condition when problem occurs environmental condition weather temperature frequency p.229
- Motorcycle condition engine condition p.229
- Motorcycle con dition p.229
- Note the above form is a standard sample it should be modified according to conditions characteristic of each market p.229
- Self diagnostic procedures p.230
- Self diagnosis reset procedure p.230
- Malfunction code and defective condition p.231
- C11 cmp sensor circuit malfunction p.233
- C12 ckp sensor circuit malfunction p.234
- C13 iap sensor circuit malfunction p.235
- Tester knob indication voltage p.236
- Replace the ecm with a new one and inspect it again p.236
- Remove the iap sensor connect the vacuum pump gauge to the vacuum port of the iap sensor arrange 3 new 1 v batteries in series check that total voltage is 4 5 v and connect terminal to the ground terminal and terminal to the vcc terminal check the voltage between vout and ground also check if voltage reduces when vacuum is applied up to 40 cmhg by using vacuum pump gauge see table below p.236
- Red g b or b br wire open or shorted to ground or poor or connection 4 22 if wire and connection are ok intermittent trouble or faulty ecm recheck each terminal and wire harness for open circuit and poor connection 4 5 p.236
- No if check result is not satis factory replace iap sensor with a new one p.236
- 09917 47010 vacuum pump gauge 09900 25008 multi circuit tester p.236
- C14 tp sensor circuit malfunction p.237
- C15 ect sensor circuit malfunction p.239
- C21 iat sensor circuit malfunction p.240
- C22 ap sensor circuit malfunction p.241
- Tester knob indication voltage p.242
- Replace the ecm with a new one and inspect it again p.242
- Remove the ap sensor connect the vacuum pump gauge to the air passage port of the ap sensor arrange 3 new 1 v batteries in series check that total voltage is 4 5 v and connect terminal to the ground terminal and terminal to the vcc terminal check the voltage between vout and ground also check if voltage reduces when vacuum is applied up to 40 cmhg by using vacuum pump gauge see table below p.242
- Red g y or b br wire open or shorted to ground or poor or connection 4 22 if wire and connection are ok intermittent trouble or faulty ecm recheck each terminal and wire harness for open circuit and poor connection 4 5 p.242
- No if check result is not satisfactory replace ap sensor with a new one p.242
- 09917 47010 vacuum pump gauge 09900 25008 multi circuit tester p.242
- C23 to sensor circuit malfunction p.243
- C28 stv actuator circuit malfunction p.244
- C24 or c25 ignition system malfunction p.244
- C29 stp sensor circuit malfunction p.245
- C31 gear position gp switch circuit malfunction p.247
- C32 or c33 fuel injection malfunction p.248
- C42 ig switch circuit malfunction p.249
- C41 fp relay circuit malfunction p.249
- S circuit malfunction p.250
- Sensor h p.250
- Fuel tank lift up p.252
- Fuel system p.252
- Fuel tank removal p.253
- Fuel tank installation p.253
- Fuel pressure inspection p.254
- Fuel pump inspection p.255
- Fuel pump relay inspection p.256
- Fuel pump and fuel filter removal p.256
- Fuel pump and fuel mesh filter installation p.258
- Fuel mesh filter inspection and cleaning p.258
- Install the new o ring and apply grease to it p.259
- Fuel pump mounting bolt 10 n m 1 kgf m 7 lb ft p.259
- 99000 32050 thread lock 1342 p.259
- 99000 25030 suzuki super grease a usa 99000 25010 suzuki super grease a others p.259
- 58 fi system p.259
- When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly in the ascending order of numbers and then tighten them to the specified torque in the above tightening order p.259
- The o ring must be replaced with a new one to prevent fuel leakage p.259
- Note apply a small quantity of the thread lock 1342 to the thread portion of the fuel pump mounting bolt p.259
- Throttle body and stv actuator p.260
- Construction p.260
- Throttle body removal p.261
- Throttle body disassembly p.262
- Never remove the stva motor yoke and motor p.264
- Throttle body reassembly p.266
- Throttle body cleaning p.266
- Inspection p.266
- Stp sensor adjustment p.269
- Tp sensor adjustment p.270
- Throttle body installation p.270
- Fuel injector inspection p.270
- Fast idle inspection p.271
- Fuel injector removal p.271
- Fuel injector installation p.271
- Fast idle adjutment p.272
- Throttle valve synchronization p.273
- Throttle cable adjustment p.274
- Tp sensor removal installation p.275
- Tp sensor inspection p.275
- Stp sensor removal installation p.275
- Stp sensor inspection p.275
- Sensor p.275
- Iap sensor removal installation p.275
- Iap sensor inspection p.275
- Cmp sensor removal installation p.276
- Cmp sensor inspection p.276
- Ckp sensor removal installation p.276
- Ckp sensor inspection p.276
- Iat sensor removal installation p.276
- Iat sensor inspection p.276
- To sensor removal installation p.277
- To sensor inspection p.277
- Sensor inspection p.277
- Ect sensor removal installation p.277
- Ect sensor inspection p.277
- Ap sensor removal installation p.277
- Ap sensor inspection p.277
- Sensor removal installation p.278
- Cooling and lubrication system p.280
- At the time of manufacture the cooling system is filled with a 50 50 mixture of distilled water and ethylene glycol anti freeze this 50 50 mixture will provide the optimum corrosion protection and excellent heat protection and will protect the cooling system from freezing at temperatures above 31 c 24 f if the motorcycle is to be exposed to temperatures below 31 c 24 f this mixing ratio should be incleased up to 55 or 60 according to the figure p.281
- Anti freeze density freezing point p.281
- Anti freeze 1 100 ml 2 1 us lmp pt water 1 100 ml 2 1 us lmp pt p.281
- 31 c 24 f 40 c 40 f 55 c 67 f p.281
- 2 cooling and lubrication system p.281
- You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot after the engine cools wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off the engine must be cool before servicing the cooling system coolant is farmful if the comes in contact with skin or eyes flush with water if swallowed accidentally induce vomiting and call physecian immediately keep it away from chiledren p.281
- Use a high quality ethylene glycol base anti freeze mixed with distilled water do not mix an alcohol base anti freeze and different brands of anti freeze do not rut in more than 60 anti freeze or less than 50 refer to right figure do not use a radiator anti leak additive p.281
- Engine coolant including reserve tank capacity p.281
- Engine coolant p.281
- Cooling circuit inspection p.282
- Cooling circuit p.282
- Removal p.283
- Radiator p.283
- Inspection and cleaning p.284
- Removal installation p.285
- Radiator reservoir tank p.285
- Radiator cap p.285
- Installation p.285
- Inspection p.285
- Water hose p.286
- Inspection p.286
- Removal p.287
- Installation p.287
- Inspection p.287
- Cooling fan p.287
- Removal p.288
- Installation p.288
- Inspection p.288
- Cooling fan thermo switch p.288
- Removal p.289
- Instalation p.289
- Inspection p.289
- Engine coolant temperature sensor p.289
- Thermostat p.290
- Removal p.290
- Inspection p.290
- Installation p.291
- Water pump p.292
- Removal and disassembly p.292
- Reassembly and installation p.294
- Inspection p.294
- Removal p.297
- Oil strainer p.297
- Oil pump p.297
- Oil pressure switch p.297
- Oil pressure regulator p.297
- Oil pressure p.297
- Oil jet p.297
- Oil filter p.297
- Oil cooler p.297
- Lubrication system p.297
- Installation p.298
- Inspection and cleaning p.298
- Engine lubrication flow chart p.299
- Engine lubrication circuit p.300
- Contents p.302
- Chassis 6 1 p.302
- Chassis p.302
- Item n m kgf m lb ft p.303
- Exterior parts p.303
- Construction p.303
- 35 3 25 p.303
- 2 chassis p.303
- Item n m kgf m lb ft p.304
- Chassis 6 3 p.304
- 50 5 36 p.304
- Removal p.305
- 23 2 16 p.309
- 100 10 72 p.309
- Item n m kgf m lb ft p.309
- Front wheel p.309
- Construction p.309
- 8 chassis p.309
- Removal p.310
- Inspection and disassembly p.310
- Reassembly and remounting p.312
- Reassemble and remount the front wheel in the reverse order of removal and disassembly pay attention to the following points p.312
- Chassis 6 11 p.312
- Item n m kgf m lb ft p.315
- Front fork p.315
- Construction p.315
- 23 2 16 p.315
- 20 2 14 p.315
- 14 chassis p.315
- Removal and disassembly p.316
- Inspection p.319
- Reassembly and remounting p.320
- Steering and handlebar p.325
- Item n m kgf m lb ft p.325
- Construction p.325
- 90 9 65 p.325
- 80 8 58 p.325
- 45 4 32 p.325
- 24 chassis p.325
- 23 2 16 p.325
- Removal p.326
- Inspection and disassembly p.329
- Reassembly and remounting p.330
- Steering tension adjustment p.333
- 23 2 16 p.334
- 100 10 72 p.334
- Rear wheel p.334
- Item n m kgf m lb ft p.334
- Construction p.334
- Chassis 6 33 p.334
- 60 6 43 p.334
- Removal p.335
- Inspection and disassembly p.336
- Reassembly and remounting p.339
- Reassemble and remount the rear wheel in the reverse order of removal and disassembly pay attention to the following points p.339
- 38 chassis p.339
- Rear shock absorber p.343
- Construction p.343
- 42 chassis p.343
- Removal p.344
- Rear shock absorber disposal p.345
- Inspection p.345
- Remounting p.346
- Suspension setting p.347
- Rear swingarm p.348
- Item n m kgf m lb ft p.348
- Construction p.348
- Chassis 6 47 p.348
- 90 9 65 p.348
- 78 7 56 p.348
- 50 5 36 p.348
- 15 1 11 p.348
- 100 10 72 p.348
- Removal p.349
- Inspection and disassembly p.350
- Reassembly p.353
- Reassemble the swingarm in the reverse order of disassembly and removal pay attention to the following points p.353
- 52 chassis p.353
- Remounting p.355
- Final inspection and adjustment p.356
- This brake system is filled with an ethylene glycol based dot 4 brake fluid do not use mix different types of fluid such as silicone based or petroleum based do not use any brake fluid taken from old used or unsealed containers never reuse brake fluid left over from the last servicing or stored for long periods when storing the brake fluid seal the container completely and keep away from children when replenishing brake fluid take care not to get dust into fluid when washing brake components use fresh brake fluid never use cleaning solvent a contaminated brake disc or brake pad reduces braking performance discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent p.357
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly p.357
- Front brake p.357
- Construction p.357
- 56 chassis p.357
- Brake pad replacement p.358
- Brake fluid replacement p.359
- Caliper removal and disassembly p.360
- Caliper inspection p.361
- Caliper reassembly and remounting p.362
- Brake disc inspection p.363
- Master cylinder removal and disas sembly p.364
- Master cylinder reassembly and remounting p.365
- Master cylinder inspection p.365
- This brake system is filled with an ethylene glycol based dot 4 brake fluid do not use or mix different types of fluid such as silicone based or petroleum based do not use any brake fluid taken from old used or unsealed containers never reuse brake fluid left over from the last servicing or stored for long periods when storing the brake fluid seal the container completely and keep away from children when replenishing brake fluid take care not to get dust into fluid when washing brake components use fresh brake fluid never use cleaning solvent a contaminated brake disc or brake pad reduces braking performance discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent p.367
- Rear brake p.367
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage them severly p.367
- Construction p.367
- 66 chassis p.367
- Brake pad replacement p.368
- Brake fluid replacement p.369
- Caliper removal and disassembly p.370
- Caliper inspection p.371
- Brake disc inspection p.372
- Caliper reassembly and remounting p.373
- Master cylinder removal and disas sembly p.374
- Master cylinder inspection p.375
- Master cylinder reassembly and remounting p.376
- Clutch release cylinder and master cylinder p.378
- Chassis 6 77 p.378
- This clutch system is filled with an ethylene glycol based dot 4 brake fluid do not use or mix different types of fluid such as silicone based or petroleum based do not use any brake fluid taken from old used or unsealed containers never reuse brake fluid left over from the last servicing or stored for long periods when storing the brake fluid seal the container completely and keep away from children when replenishing brake fluid take care not to get dust into fluid when washing brake components use fresh brake fluid never use cleaning solvent p.378
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage them sererly p.378
- Construction p.378
- Clutch release cylinder removal and disassembly p.379
- Clutch fluid replacement p.379
- Clutch release cylinder reassem bly and remounting p.380
- Clutch release cylinder inspection p.380
- Clutch master cylinder removal and disassembly p.382
- Clutch master cylinder reassembly and remounting p.383
- Clutch master cylinder inspection p.383
- Tire removal p.385
- Tire and wheel p.385
- Inspection p.385
- Valve installation p.386
- Tire installation p.386
- Electrical system p.388
- Semi conductor equipped part p.389
- Coupler p.389
- Connector p.389
- Cautions in servicing p.389
- Wiring procedure p.390
- Using the multi circuit tester p.390
- Connecting the battery p.390
- Battery p.390
- Location of electrical components p.391
- 4 electrical system p.391
- Electrical system 7 5 p.392
- Troubleshooting p.393
- Charging system p.393
- Inspection p.394
- Trouble shooting p.397
- Starter system and side stand ignition interlock system p.397
- Starter motor removal and disassembly p.398
- Starter motor reassembly p.399
- Starter motor inspection p.399
- Starter relay inspection p.400
- Side stand ignition interlock system parts inspection p.401
- On side stand up p.401
- Pink black p.402
- Low to top gear position except neutral position p.402
- Unit v p.403
- More than 1 v p.403
- No spark or poor spark p.404
- Loose poor connection of couplers p.404
- Ignition system p.404
- Correct p.404
- Continued on next page p.404
- Check that the transmission is in neutral and the engine stop switch is in the run position pull the clutch lever check that the fuse is not blown and the battery is fully charged before diagnosing p.404
- Troubleshooting p.404
- Inspection p.406
- Removal and disassembly p.409
- Combination meter p.409
- Time ignition switch set switch p.410
- Release p.410
- Push reset p.410
- Inspection p.410
- Engine coolant temperature meter and indicator p.412
- Resistance more than 167 ω less than 21 ω 115 167 ω 73 115 ω 45 73 ω 22 45 ω p.414
- Fuel level meter p.414
- Note to adjust the headlight beam adjust the beam horizontally first then adjust the vertically p.416
- Vertical adjuster p.416
- Headlight brake light taillight and turn signal light p.416
- Headlight beam adjustment adjust the headlight beam both vertical and horizontal p.416
- Fuel pump relay p.417
- Turn signal side stand relay p.417
- Starter relay p.417
- Relays p.417
- Switches p.418
- Lighting switch except for e03 e24 e28 e33 p.419
- Inspect each switch for continuity with a tester if any abnormality is found replace the respective switch assemblies with new ones p.419
- Ignition switch for e24 p.419
- Horn button p.419
- Hazard except for e03 e24 e28 e33 p.419
- Front brake switch p.419
- For others p.419
- Engine stop swich p.419
- Dimmer switch p.419
- Wire color p.419
- Clutch lever position switch p.419
- Turn signal switch p.419
- B black br brown gr gray lbl light blue lg light green o orange r red y yellow w white bl blue g green p.419
- Starter button p.419
- B bl black with blue tracer b w black with white tracer b y black with yellow tracer b r black with red tracer g y green with yellow tracer o b orange with black tracer o bl orange with blue tracer o g orange with green tracer o r orange with red tracer o w orange with white tracer o y orange with yellow tracer w b white with black tracer y g yellow with green tracer y w yellow with white tracer p.419
- Rear brake switch p.419
- Passing light switch except for e03 e28 e33 p.419
- Oil pressure switch for e03 e24 e28 e33 p.419
- Note before inspecting the oil pressure switch check the engine oil level 2 13 p.419
- Specifications p.420
- Initial charging p.420
- Battery p.420
- Servicing p.422
- Recharging operation p.422
- Servicing information p.424
- Troubleshooting p.425
- Fi system malfunction code and defective condition p.425
- Engine p.427
- Radiator cooling system p.432
- Chassis p.433
- Brakes p.434
- Electrical p.435
- Battery p.436
- Wire harness routing p.437
- Wire harness cable and hose routing p.437
- 14 servicing information p.437
- Servicing information 8 15 p.438
- 16 servicing information p.439
- Servicing information 8 17 p.440
- Engine electrical parts set up p.440
- High tension cord routing p.441
- 18 servicing information p.441
- Throttle cable routing p.442
- Servicing information 8 19 p.442
- View of top p.443
- Throttle body installation hose routing p.443
- 20 servicing information p.443
- Servicing information 8 21 p.444
- Crankcase breather hose routing p.444
- View b p.445
- View a p.445
- Clutch hose routing p.445
- 22 servicing information p.445
- Servicing information 8 23 p.446
- Cooling system hose routing p.446
- View c p.447
- View b p.447
- View a p.447
- Front brake hose routing p.447
- 24 servicing information p.447
- View d view c p.448
- View b p.448
- View a p.448
- Servicing information 8 25 p.448
- Rear brake hose routing p.448
- Fuel tank drain hose routing p.449
- 26 servicing information p.449
- Servicing information 8 27 p.450
- Fuel tank installation p.450
- Pair air supply system hose routing p.451
- 28 servicing information p.451
- Seat lock cable routing p.452
- Side stand set up p.453
- Brake pedal footrest set up p.453
- 30 servicing information p.453
- Footrest set up p.454
- Servicing information 8 31 p.454
- Note after installing the rh balancer weight check that throttle grip rotate smoothly by turning it p.454
- Handlebar balancer installation p.454
- Special tools p.455
- Note when ordering a special tool please confirm whether it is available or not p.457
- Tightening torque p.458
- Engine p.458
- Fi system parts p.459
- Chassis p.460
- Tightening torque chart p.461
- Valve guide p.462
- Service data p.462
- Cylinder piston piston ring p.463
- Camshaft cylinder head p.463
- Conrod crankshaft p.464
- Clutch p.465
- Thermostat radiator fan p.465
- Oil pump p.465
- Injector fuel pump fuel pressure regurator p.466
- Drive train p.466
- Throttle body p.467
- Fi sensors p.467
- Electrical p.468
- Wattage p.469
- Brake wheel p.469
- Tire pressure p.470
- Suspension p.470
- Fuel oil engine coolant p.471
- Emission control information p.472
- Emission control systems p.473
- Dl1000 motorcycles are equipped with a fuel injection system for emission level control this fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits p.473
- 2 emission control information p.473
- Fuel injection system p.473
- The engine is equipped with a pcv system blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the breather hose air cleaner and throttle body p.474
- Emission control information 9 3 p.474
- Crankcase emission control system p.474
- The exhaust emission control system is composed of the pair system and three way catalyst sys tem the fresh air is drawn into the exhaust port with the pair solenoid valve and pair reed valve the pair solenoid valve is operated by the ecm and the fresh air flow is controlled according to the tps ects iats iaps and ckps p.475
- Exhaust emission control system pair system p.475
- 4 emission control information p.475
- Tampering with the noise control system prohibited local law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person p.476
- Noise emission control system p.476
- Evaporative emission control system only for e 33 p.476
- Emission control information 9 5 p.476
- Among those acts presumed to constitute tampering are the acts listed below removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases removing or puncturing the air cleaner case air cleaner cover baffles or any other component which conducts intake air replacing the exhaust system or muffler with a system or muffler not marked with the same model spe cific code as the code listed on the motorcycle noise emission control information label p.476
- Pair reed valve p.477
- Pair control valve for e 03 24 28 and 33 p.477
- Pair air supply system inspection p.477
- Pair control solenoid valve for e 02 and 19 p.478
- Pair air supply system hose routing p.479
- 8 emission control information p.479
- S inspection p.480
- Heated oxgen sensor h p.480
- Heated oxgen sensor wire routing p.481
- 10 emission control information p.481
- Evaporative emission control system inspection only for e 33 p.482
- Canister p.482
- Canister hose routing only for e 33 p.483
- 12 emission control information p.483
- Specifications 0 2 service data 0 4 front fork 0 14 regulator rectifier inspection 0 15 p.484
- Dl1000k3 03 model p.484
- Contents p.484
- Engine p.485
- Drive train p.485
- Dimensions and dry mass p.485
- Specifications p.485
- Electrical p.486
- Chassis p.486
- Capacities p.486
- Valve guide p.487
- Service data p.487
- Cylinder piston piston ring p.488
- Camshaft cylinder head p.488
- Conrod crankshaft p.489
- Thermostat radiator fan p.490
- Oil pump p.490
- Clutch p.490
- Injector fuel pump fuel pressure regurator p.491
- Drive train p.491
- Throttle body p.492
- Fi sensors p.492
- Electrical p.493
- Wattage p.494
- Brake wheel p.494
- Tire pressure p.495
- Suspension p.495
- Fuel oil engine coolant p.496
- Item n m kgf m lb ft p.497
- Front fork p.497
- Construction p.497
- 23 2 16 p.497
- 20 2 14 p.497
- 14 dl1000k3 03 model p.497
- Suspension setting p.498
- Regulator rectifier inspection p.498
- Dl1000k4 04 model p.500
- Contents p.500
- Specifications p.501
- 2 dl1000k4 04 model p.501
- Valve guide p.502
- Service data p.502
- Cylinder piston piston ring p.503
- Camshaft cylinder head p.503
- Conrod crankshaft p.504
- Thermostat radiator fan p.505
- Oil pump p.505
- Clutch p.505
- Injector fuel pump fuel pressure regurator p.506
- Drive train p.506
- Throttle body p.507
- Fi sensors p.507
- Electrical p.508
- Brake wheel p.509
- Wattage p.509
- Tire pressure p.510
- Suspension p.510
- Special tool p.511
- Fuel oil engine coolant p.511
- Periodic maintenance chart p.512
- Remount the engine in the reverse order of engine removal pay attention to the following points p.513
- Note the engine mounting nuts are self locking once the nut has been removed it is no longer of any use be sure to use new nuts and then tighten them to the specified torque p.513
- Engine installation p.513
- 14 dl1000k4 04 model p.513
- Fi system p.514
- Removal and disassembly p.515
- Combination meter p.515
- Release p.516
- Push reset p.516
- Inspection p.516
- Time ignition switch adj switch p.516
- Indicators p.518
- Wire harness routing p.521
- 22 dl1000k4 04 model p.521
- Dl1000k4 04 model 11 23 p.522
- Item n m kgf m lb ft p.523
- Cowling setup p.523
- 35 3 25 p.523
- 24 dl1000k4 04 model p.523
- Wiring diagram p.524
- Fi system wiring diagram p.524
- Optional parts p.525
- Handlebar switch r p.525
- Handlebar switch l p.525
- Grip heater p.525
- E 02 19 p.525
- Wiring diagram p.525
- Starter switch p.526
- Speedometer light tachometer light neutral indicator light high beam indicator light oil pressure indicator light turn signal indicator light r turn signal indicator light l fi indicatior light od indicator light ect indicator light p.526
- Sp ta n h o r l fi od w p.526
- Optional parts p.526
- Handlebar switch r p.526
- Handlebar switch l p.526
- Grip heater p.526
- E 03 28 33 p.526
- Starter switch p.527
- Speedometer light tachometer light neutral indicator light high beam indicator light oil pressure indicator light turn signal indicator light r turn signal indicator light l fi indicatior light od indicator light ect indicator light p.527
- Sp ta n h o r l fi od w p.527
- Optional parts p.527
- Handlebar switch r p.527
- Handlebar switch l p.527
- Grip heater p.527
- Model application p.529
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