![Kawasaki KLV1000 (2004) [90/529] Engine removal and installation](/img/pdf.png)
Kawasaki KLV1000 (2004) [90/529] Engine removal and installation
![Kawasaki KLV1000 (2004) [90/529] Engine removal and installation](/views2/1121213/page90/bg5a.png)
ENGINE 3-3
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine
using a steam cleaner. Engine removal is sequentially explained
in the following steps. Reinstall the engine by reversing the
removal procedure.
• Drain engine oil. (2-12)
• Drain engine coolant. (2-17)
• Remove the seat. (6-4)
• Disconnect the battery
lead wire.
• Remove the engine under cover
.
• Remove the fuel tank side covers
, cowlings
and inner
cowling. (6-6)
• Remove the radiator and water hoses.
Содержание
- Klv1000 1
- Kawasaki heavy industries ltd first edition 1 feb 12 2004 k 2
- Klv1000 2
- Motorcycle service manual supplement 2
- Caution 4
- Foreword 4
- How to use this manual 4
- Warning 4
- Symbol 5
- Contents 8
- General information 8
- General information 1 1 8
- General information 1 2 9
- General precautions 9
- Kawasaki lv1000 a1 10
- General information 1 4 11
- Specifications 11
- General information 1 5 12
- Country and area codes 13
- General information 1 6 13
- Contents 14
- Periodic maintenance 14
- Periodic maintenance 2 1 14
- I inspect and clean adjust replace or lubricate as necessary r replace t tighten c clean 15
- Note more frequent servicing may be performed on motorcycles that are use under severe conditions 15
- Periodic maintenance 2 2 15
- Periodic maintenance chart 15
- Periodic maintenance schedule 15
- 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 15
- 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 16
- Periodic maintenance 2 3 16
- Valve clearance adjustment chart inlet valve 16
- Exhaust 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 17
- Periodic maintenance 2 4 17
- Valve clearance adjustment chart exhaust valve 17
- Contents 18
- Engine 18
- Engine 3 1 18
- Contents 20
- Fi system 20
- Fi system 4 1 20
- Fi system 4 2 21
- Contents 22
- Cooling system 22
- Cooling system 5 1 22
- Cooling system 5 2 23
- Chassis 24
- Contents 24
- Contents 26
- Electrical system 26
- Electrical system 7 1 26
- Contents 28
- Servicing information 28
- Servicing information 8 1 28
- Servicing information 8 2 29
- Special tools 29
- Servicing information 8 3 30
- Servicing information 8 4 31
- Servicing information 8 5 32
- Servicing information 8 6 33
- Servicing information 8 7 34
- Servicing information 8 8 35
- Servicing information 8 9 36
- Contents 38
- Emission control information 38
- Emission control information 9 1 38
- Base manual 40
- Suzuki dl1000 40
- Chassis 42
- Cooling and lubrication system 42
- Dl1000k3 03 model 42
- Dl1000k4 04 model 42
- Electrical system 42
- Emission control information 42
- Engine 42
- Fi system 42
- Foreword 42
- General information 42
- Group index 42
- Periodic maintenance 42
- Servicing information 42
- Wiring diagram 42
- 100 10 72 43
- 23 2 16 43
- Component parts and work to be done 43
- Example front wheel 43
- How to use this manual 43
- Item n m kgf m lb ft 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 43
- To locate what you are looking for 43
- 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 43
- 32110 use special tool 44
- Apply or use brake fluid 44
- Apply suzuki bond 1207b 99000 31140 measure in current range 44
- Apply suzuki bond 1215 99000 31110 measure in diode test range 44
- Apply suzuki moly paste 99000 25140 measure in voltage range 44
- Apply thread lock super 1303 99000 32030 measure in continuity test range 44
- Symbol 44
- Use fork oil 44
- Abbreviations used in this manual 45
- General information 48
- General precautions 49
- Warning caution note 49
- Fuel for canadian model 51
- Fuel for other countries 51
- Fuel oil and engine coolant recommendation 51
- Right side left side 51
- Serial number location 51
- Suzuki dl1000k2 02 model 51
- Anti freeze engine coolant 52
- Brake fluid 52
- Engine coolant 52
- Engine oil 52
- Front fork oil 52
- Liquid amount of water engine coolant 52
- Water for mixing 52
- Break ln procedures 53
- Cylinder identification 53
- General information 1 7 54
- Information labels 54
- Dimensions and dry mass 55
- Drive train 55
- Engine 55
- Specifications 55
- Capacities 56
- Chassis 56
- Electrical 56
- Country and area codes 57
- Periodic maintenance 58
- Periodic maintenance chart 59
- Periodic maintenance schedule 59
- Lubrication points 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 60
- Periodic maintenance 2 3 60
- Proper lubrication is important for smooth operation and long life of each working part of the motorcycle major lubrication points are indicated below 60
- Air cleaner 61
- Maintenance and tune up pro cedures 61
- Spark plug 62
- Tappet clearance 64
- Intake side 67
- Exhaust side 68
- Engine oil and oil filter 69
- Fuel hose 69
- Engine idle speed 71
- Throttle cable play 71
- Pair air supply system 72
- Throttle valve synchronization 72
- Clutch 73
- Cooling system 74
- Drive chain 76
- Steering 82
- Exhaust pipe bolt 83
- Front fork 83
- Rear suspension 83
- Chassis bolt and nut 84
- 1 400 kpa 10 14 kgf c 86
- 199 psi 86
- Compression pressure check 86
- Compression test procedure 86
- Kpa 2 kgf c 86
- Kpa 8 kgf c 86
- Oil pressure check 87
- Oil pressure test procedure 87
- Engine 88
- Engine components removable with engine in place 89
- Engine removal 90
- Engine removal and installation 90
- 12 engine 99
- Engine installation 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 99
- Remount the engine in the reverse order of engine removal pay attention to the following points 99
- Engine disassembly 106
- Engine top side 106
- Engine bottom side 112
- Cylinder head cover 121
- Engine components inspection and servicing 121
- Camshaft cylinder head 122
- Cylinder piston inspection 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 135
- Conrod crankshaft 137
- Clutch 141
- 56 engine 143
- Construction 143
- Transmission 143
- Gearshift fork 149
- Primary drive gear 150
- Starter torque limiter 151
- Starter clutch 152
- Crankcase 153
- Gearshift 153
- Crankcase crankshaft bearing 158
- Clutch cover 164
- Gearshift cover 164
- Generator cover 164
- Engine bottom side 165
- Engine reassembly 165
- Clutch cover install the gasket and dowel pins 176
- Drive plate no drive plate pcs no drive plate pc no drive plate pc 176
- Driven plate no driven plate 8 pcs standard 7pcs no driven plate 4 pcs standard 2pcs 176
- Engine 3 89 176
- 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 176
- Use the new gasket to prevent oil leakage 176
- Engine top side 179
- No 1 front cylinder tdc of compression stroke 192
- No front cylinder head 194
- No rear cylinder head 196
- No 1 front cylinder tdc of compression stroke 197
- Contents 201
- Fi system 201
- Connector coupler 203
- Precautions in servicing 203
- Ecm various sensors 204
- Electrical circuit inspection procedure 206
- Using testers 209
- Fi system technical features 210
- Injection time injection volume 210
- Compensation of injection time volume 211
- Injection stop control 211
- 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 212
- Fi system 4 11 212
- Fuel delivery system 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 212
- 12 fi system 213
- 64 85 psi 213
- Fuel pump 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 213
- 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 213
- Fuel injector 214
- Fuel pressure regulator 214
- 14 fi system 215
- Fuel pump control system 215
- 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 215
- Ecm fi control unit 216
- Injection timing 216
- Sensors 217
- 20 fi system 221
- Fi system parts location 221
- Fi system 4 21 222
- 22 fi system 223
- Fi system wiring diagram 223
- Self diagnosis function 224
- User mode 224
- Dealer mode 225
- Incorrect 226
- Position correcte 226
- Tps adjustment 226
- Fail safe function 227
- Customer complaint analysis 228
- Fi system troubleshooting 228
- Motorcycle con dition 229
- Motorcycle condition engine condition 229
- Motorcycle environmental condition when problem occurs environmental condition weather temperature frequency 229
- Note the above form is a standard sample it should be modified according to conditions characteristic of each market 229
- Self diagnosis reset procedure 230
- Self diagnostic procedures 230
- Malfunction code and defective condition 231
- C11 cmp sensor circuit malfunction 233
- C12 ckp sensor circuit malfunction 234
- C13 iap sensor circuit malfunction 235
- 09917 47010 vacuum pump gauge 09900 25008 multi circuit tester 236
- No if check result is not satis factory replace iap sensor with a new one 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 5 236
- 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 236
- Replace the ecm with a new one and inspect it again 236
- Tester knob indication voltage 236
- C14 tp sensor circuit malfunction 237
- C15 ect sensor circuit malfunction 239
- C21 iat sensor circuit malfunction 240
- C22 ap sensor circuit malfunction 241
- 09917 47010 vacuum pump gauge 09900 25008 multi circuit tester 242
- No if check result is not satisfactory replace ap sensor with a new one 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 5 242
- 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 242
- Replace the ecm with a new one and inspect it again 242
- Tester knob indication voltage 242
- C23 to sensor circuit malfunction 243
- C24 or c25 ignition system malfunction 244
- C28 stv actuator circuit malfunction 244
- C29 stp sensor circuit malfunction 245
- C31 gear position gp switch circuit malfunction 247
- C32 or c33 fuel injection malfunction 248
- C41 fp relay circuit malfunction 249
- C42 ig switch circuit malfunction 249
- S circuit malfunction 250
- Sensor h 250
- Fuel system 252
- Fuel tank lift up 252
- Fuel tank installation 253
- Fuel tank removal 253
- Fuel pressure inspection 254
- Fuel pump inspection 255
- Fuel pump and fuel filter removal 256
- Fuel pump relay inspection 256
- Fuel mesh filter inspection and cleaning 258
- Fuel pump and fuel mesh filter installation 258
- 58 fi system 259
- 99000 25030 suzuki super grease a usa 99000 25010 suzuki super grease a others 259
- 99000 32050 thread lock 1342 259
- Fuel pump mounting bolt 10 n m 1 kgf m 7 lb ft 259
- Install the new o ring and apply grease to it 259
- Note apply a small quantity of the thread lock 1342 to the thread portion of the fuel pump mounting bolt 259
- The o ring must be replaced with a new one to prevent fuel leakage 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 259
- Construction 260
- Throttle body and stv actuator 260
- Throttle body removal 261
- Throttle body disassembly 262
- Never remove the stva motor yoke and motor 264
- Inspection 266
- Throttle body cleaning 266
- Throttle body reassembly 266
- Stp sensor adjustment 269
- Fuel injector inspection 270
- Throttle body installation 270
- Tp sensor adjustment 270
- Fast idle inspection 271
- Fuel injector installation 271
- Fuel injector removal 271
- Fast idle adjutment 272
- Throttle valve synchronization 273
- Throttle cable adjustment 274
- Iap sensor inspection 275
- Iap sensor removal installation 275
- Sensor 275
- Stp sensor inspection 275
- Stp sensor removal installation 275
- Tp sensor inspection 275
- Tp sensor removal installation 275
- Ckp sensor inspection 276
- Ckp sensor removal installation 276
- Cmp sensor inspection 276
- Cmp sensor removal installation 276
- Iat sensor inspection 276
- Iat sensor removal installation 276
- Ap sensor inspection 277
- Ap sensor removal installation 277
- Ect sensor inspection 277
- Ect sensor removal installation 277
- Sensor inspection 277
- To sensor inspection 277
- To sensor removal installation 277
- Sensor removal installation 278
- Cooling and lubrication system 280
- 2 cooling and lubrication system 281
- 31 c 24 f 40 c 40 f 55 c 67 f 281
- Anti freeze 1 100 ml 2 1 us lmp pt water 1 100 ml 2 1 us lmp pt 281
- Anti freeze density freezing point 281
- 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 281
- Engine coolant 281
- Engine coolant including reserve tank capacity 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 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 281
- Cooling circuit 282
- Cooling circuit inspection 282
- Radiator 283
- Removal 283
- Inspection and cleaning 284
- Inspection 285
- Installation 285
- Radiator cap 285
- Radiator reservoir tank 285
- Removal installation 285
- Inspection 286
- Water hose 286
- Cooling fan 287
- Inspection 287
- Installation 287
- Removal 287
- Cooling fan thermo switch 288
- Inspection 288
- Installation 288
- Removal 288
- Engine coolant temperature sensor 289
- Inspection 289
- Instalation 289
- Removal 289
- Inspection 290
- Removal 290
- Thermostat 290
- Installation 291
- Removal and disassembly 292
- Water pump 292
- Inspection 294
- Reassembly and installation 294
- Lubrication system 297
- Oil cooler 297
- Oil filter 297
- Oil jet 297
- Oil pressure 297
- Oil pressure regulator 297
- Oil pressure switch 297
- Oil pump 297
- Oil strainer 297
- Removal 297
- Inspection and cleaning 298
- Installation 298
- Engine lubrication flow chart 299
- Engine lubrication circuit 300
- Chassis 302
- Chassis 6 1 302
- Contents 302
- 2 chassis 303
- 35 3 25 303
- Construction 303
- Exterior parts 303
- Item n m kgf m lb ft 303
- 50 5 36 304
- Chassis 6 3 304
- Item n m kgf m lb ft 304
- Removal 305
- 100 10 72 309
- 23 2 16 309
- 8 chassis 309
- Construction 309
- Front wheel 309
- Item n m kgf m lb ft 309
- Inspection and disassembly 310
- Removal 310
- Chassis 6 11 312
- Reassemble and remount the front wheel in the reverse order of removal and disassembly pay attention to the following points 312
- Reassembly and remounting 312
- 14 chassis 315
- 20 2 14 315
- 23 2 16 315
- Construction 315
- Front fork 315
- Item n m kgf m lb ft 315
- Removal and disassembly 316
- Inspection 319
- Reassembly and remounting 320
- 23 2 16 325
- 24 chassis 325
- 45 4 32 325
- 80 8 58 325
- 90 9 65 325
- Construction 325
- Item n m kgf m lb ft 325
- Steering and handlebar 325
- Removal 326
- Inspection and disassembly 329
- Reassembly and remounting 330
- Steering tension adjustment 333
- 100 10 72 334
- 23 2 16 334
- 60 6 43 334
- Chassis 6 33 334
- Construction 334
- Item n m kgf m lb ft 334
- Rear wheel 334
- Removal 335
- Inspection and disassembly 336
- 38 chassis 339
- Reassemble and remount the rear wheel in the reverse order of removal and disassembly pay attention to the following points 339
- Reassembly and remounting 339
- 42 chassis 343
- Construction 343
- Rear shock absorber 343
- Removal 344
- Inspection 345
- Rear shock absorber disposal 345
- Remounting 346
- Suspension setting 347
- 100 10 72 348
- 15 1 11 348
- 50 5 36 348
- 78 7 56 348
- 90 9 65 348
- Chassis 6 47 348
- Construction 348
- Item n m kgf m lb ft 348
- Rear swingarm 348
- Removal 349
- Inspection and disassembly 350
- 52 chassis 353
- Reassemble the swingarm in the reverse order of disassembly and removal pay attention to the following points 353
- Reassembly 353
- Remounting 355
- Final inspection and adjustment 356
- 56 chassis 357
- Construction 357
- Front brake 357
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly 357
- 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 357
- Brake pad replacement 358
- Brake fluid replacement 359
- Caliper removal and disassembly 360
- Caliper inspection 361
- Caliper reassembly and remounting 362
- Brake disc inspection 363
- Master cylinder removal and disas sembly 364
- Master cylinder inspection 365
- Master cylinder reassembly and remounting 365
- 66 chassis 367
- Construction 367
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage them severly 367
- Rear brake 367
- 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 367
- Brake pad replacement 368
- Brake fluid replacement 369
- Caliper removal and disassembly 370
- Caliper inspection 371
- Brake disc inspection 372
- Caliper reassembly and remounting 373
- Master cylinder removal and disas sembly 374
- Master cylinder inspection 375
- Master cylinder reassembly and remounting 376
- Chassis 6 77 378
- Clutch release cylinder and master cylinder 378
- Construction 378
- Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage them sererly 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 378
- Clutch fluid replacement 379
- Clutch release cylinder removal and disassembly 379
- Clutch release cylinder inspection 380
- Clutch release cylinder reassem bly and remounting 380
- Clutch master cylinder removal and disassembly 382
- Clutch master cylinder inspection 383
- Clutch master cylinder reassembly and remounting 383
- Inspection 385
- Tire and wheel 385
- Tire removal 385
- Tire installation 386
- Valve installation 386
- Electrical system 388
- Cautions in servicing 389
- Connector 389
- Coupler 389
- Semi conductor equipped part 389
- Battery 390
- Connecting the battery 390
- Using the multi circuit tester 390
- Wiring procedure 390
- 4 electrical system 391
- Location of electrical components 391
- Electrical system 7 5 392
- Charging system 393
- Troubleshooting 393
- Inspection 394
- Starter system and side stand ignition interlock system 397
- Trouble shooting 397
- Starter motor removal and disassembly 398
- Starter motor inspection 399
- Starter motor reassembly 399
- Starter relay inspection 400
- On side stand up 401
- Side stand ignition interlock system parts inspection 401
- Low to top gear position except neutral position 402
- Pink black 402
- More than 1 v 403
- Unit v 403
- 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 404
- Continued on next page 404
- Correct 404
- Ignition system 404
- Loose poor connection of couplers 404
- No spark or poor spark 404
- Troubleshooting 404
- Inspection 406
- Combination meter 409
- Removal and disassembly 409
- Inspection 410
- Push reset 410
- Release 410
- Time ignition switch set switch 410
- Engine coolant temperature meter and indicator 412
- Fuel level meter 414
- Resistance more than 167 ω less than 21 ω 115 167 ω 73 115 ω 45 73 ω 22 45 ω 414
- Headlight beam adjustment adjust the headlight beam both vertical and horizontal 416
- Headlight brake light taillight and turn signal light 416
- Note to adjust the headlight beam adjust the beam horizontally first then adjust the vertically 416
- Vertical adjuster 416
- Fuel pump relay 417
- Relays 417
- Starter relay 417
- Turn signal side stand relay 417
- Switches 418
- 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 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 419
- Clutch lever position switch 419
- Dimmer switch 419
- Engine stop swich 419
- For others 419
- Front brake switch 419
- Hazard except for e03 e24 e28 e33 419
- Horn button 419
- Ignition switch for e24 419
- Inspect each switch for continuity with a tester if any abnormality is found replace the respective switch assemblies with new ones 419
- Lighting switch except for e03 e24 e28 e33 419
- Note before inspecting the oil pressure switch check the engine oil level 2 13 419
- Oil pressure switch for e03 e24 e28 e33 419
- Passing light switch except for e03 e28 e33 419
- Rear brake switch 419
- Starter button 419
- Turn signal switch 419
- Wire color 419
- Battery 420
- Initial charging 420
- Specifications 420
- Recharging operation 422
- Servicing 422
- Servicing information 424
- Fi system malfunction code and defective condition 425
- Troubleshooting 425
- Engine 427
- Radiator cooling system 432
- Chassis 433
- Brakes 434
- Electrical 435
- Battery 436
- 14 servicing information 437
- Wire harness cable and hose routing 437
- Wire harness routing 437
- Servicing information 8 15 438
- 16 servicing information 439
- Engine electrical parts set up 440
- Servicing information 8 17 440
- 18 servicing information 441
- High tension cord routing 441
- Servicing information 8 19 442
- Throttle cable routing 442
- 20 servicing information 443
- Throttle body installation hose routing 443
- View of top 443
- Crankcase breather hose routing 444
- Servicing information 8 21 444
- 22 servicing information 445
- Clutch hose routing 445
- View a 445
- View b 445
- Cooling system hose routing 446
- Servicing information 8 23 446
- 24 servicing information 447
- Front brake hose routing 447
- View a 447
- View b 447
- View c 447
- Rear brake hose routing 448
- Servicing information 8 25 448
- View a 448
- View b 448
- View d view c 448
- 26 servicing information 449
- Fuel tank drain hose routing 449
- Fuel tank installation 450
- Servicing information 8 27 450
- 28 servicing information 451
- Pair air supply system hose routing 451
- Seat lock cable routing 452
- 30 servicing information 453
- Brake pedal footrest set up 453
- Side stand set up 453
- Footrest set up 454
- Handlebar balancer installation 454
- Note after installing the rh balancer weight check that throttle grip rotate smoothly by turning it 454
- Servicing information 8 31 454
- Special tools 455
- Note when ordering a special tool please confirm whether it is available or not 457
- Engine 458
- Tightening torque 458
- Fi system parts 459
- Chassis 460
- Tightening torque chart 461
- Service data 462
- Valve guide 462
- Camshaft cylinder head 463
- Cylinder piston piston ring 463
- Conrod crankshaft 464
- Clutch 465
- Oil pump 465
- Thermostat radiator fan 465
- Drive train 466
- Injector fuel pump fuel pressure regurator 466
- Fi sensors 467
- Throttle body 467
- Electrical 468
- Brake wheel 469
- Wattage 469
- Suspension 470
- Tire pressure 470
- Fuel oil engine coolant 471
- Emission control information 472
- 2 emission control information 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 473
- Emission control systems 473
- Fuel injection system 473
- Crankcase emission control system 474
- Emission control information 9 3 474
- 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 474
- 4 emission control information 475
- Exhaust emission control system pair system 475
- 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 475
- 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 476
- Emission control information 9 5 476
- Evaporative emission control system only for e 33 476
- Noise emission control system 476
- 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 476
- Pair air supply system inspection 477
- Pair control valve for e 03 24 28 and 33 477
- Pair reed valve 477
- Pair control solenoid valve for e 02 and 19 478
- 8 emission control information 479
- Pair air supply system hose routing 479
- Heated oxgen sensor h 480
- S inspection 480
- 10 emission control information 481
- Heated oxgen sensor wire routing 481
- Canister 482
- Evaporative emission control system inspection only for e 33 482
- 12 emission control information 483
- Canister hose routing only for e 33 483
- Contents 484
- Dl1000k3 03 model 484
- Specifications 0 2 service data 0 4 front fork 0 14 regulator rectifier inspection 0 15 484
- Dimensions and dry mass 485
- Drive train 485
- Engine 485
- Specifications 485
- Capacities 486
- Chassis 486
- Electrical 486
- Service data 487
- Valve guide 487
- Camshaft cylinder head 488
- Cylinder piston piston ring 488
- Conrod crankshaft 489
- Clutch 490
- Oil pump 490
- Thermostat radiator fan 490
- Drive train 491
- Injector fuel pump fuel pressure regurator 491
- Fi sensors 492
- Throttle body 492
- Electrical 493
- Brake wheel 494
- Wattage 494
- Suspension 495
- Tire pressure 495
- Fuel oil engine coolant 496
- 14 dl1000k3 03 model 497
- 20 2 14 497
- 23 2 16 497
- Construction 497
- Front fork 497
- Item n m kgf m lb ft 497
- Regulator rectifier inspection 498
- Suspension setting 498
- Contents 500
- Dl1000k4 04 model 500
- 2 dl1000k4 04 model 501
- Specifications 501
- Service data 502
- Valve guide 502
- Camshaft cylinder head 503
- Cylinder piston piston ring 503
- Conrod crankshaft 504
- Clutch 505
- Oil pump 505
- Thermostat radiator fan 505
- Drive train 506
- Injector fuel pump fuel pressure regurator 506
- Fi sensors 507
- Throttle body 507
- Electrical 508
- Brake wheel 509
- Wattage 509
- Suspension 510
- Tire pressure 510
- Fuel oil engine coolant 511
- Special tool 511
- Periodic maintenance chart 512
- 14 dl1000k4 04 model 513
- Engine installation 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 513
- Remount the engine in the reverse order of engine removal pay attention to the following points 513
- Fi system 514
- Combination meter 515
- Removal and disassembly 515
- Inspection 516
- Push reset 516
- Release 516
- Time ignition switch adj switch 516
- Indicators 518
- 22 dl1000k4 04 model 521
- Wire harness routing 521
- Dl1000k4 04 model 11 23 522
- 24 dl1000k4 04 model 523
- 35 3 25 523
- Cowling setup 523
- Item n m kgf m lb ft 523
- Fi system wiring diagram 524
- Wiring diagram 524
- E 02 19 525
- Grip heater 525
- Handlebar switch l 525
- Handlebar switch r 525
- Optional parts 525
- Wiring diagram 525
- E 03 28 33 526
- Grip heater 526
- Handlebar switch l 526
- Handlebar switch r 526
- Optional parts 526
- Sp ta n h o r l fi od w 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 526
- Starter switch 526
- Grip heater 527
- Handlebar switch l 527
- Handlebar switch r 527
- Optional parts 527
- Sp ta n h o r l fi od w 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 527
- Starter switch 527
- Model application 529
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