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TL1000R (1998-2002)
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Suzuki TL1000R (1998-2002) [2/512] Tl 1000r

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Ùupbituwbiùpun uo 1
Service manual 2
Tl 1000r 2
A warning 3
Chassis 3
Cooling system 3
Electrical system 3
Emission control information 3
Engine 3
Fl system and intake air system 3
Foreword 3
General information 3
Group index 3
Important 3
Periodic maintenance 3
Servicing information 3
Suzuki motor corporation 3
Component parts and work to be done 4
How to use this manual 4
To locate what you are looking for 4
Symbol 5
Abbreviations may be used in this manual 6
Sae to former suzuki term only for u s a 7
General info 9
General information 9
Awarning 10
General precautions 10
Warning caution note 10
Fuel oil and engine coolant recommendation 12
Serial number location 12
Suzuki tl1000rw 98 model 12
A warning 13
Anti freeze engine coolant 13
Brake fluid 13
Engine coolant 13
Engine oil 13
Front fork oil 13
Liquid amount of water engine coolant 13
Water for mixing 13
Break in procedures 14
Cylinder identification 14
General information 1 6 15
Dimensions and dry mass 16
Engine 16
Specifications 16
Transmission 16
Capacities 17
Chassis 17
Electrical 17
Country and area codes 18
Periodic maintanance 19
Periodic maintenance 19
Periodic maintenance chart 20
Periodic maintenance schedule 20
Cycle has been operated under wet or rainy conditions 21
Lubrication points 21
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 motor 21
Periodic maintenance 2 2 21
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle major lubrication points are indicated below 21
Air cleaner 22
Maintenance and tune up procedures 22
A warning 23
Spark plug 23
Tappet clearance 25
9 periodic maintenance 28
How to use this chart 28
Option 28
Tappet shim selection table intake z 28
Tappet shim set 12800 41810 28
Option гаррет shim set 12800 41810 29
Periodic maintenance 2 10 29
Tappet shim no 12892 41с00 ххх 29
Tappet shim selection table exhaust 29
Engine oil and oil filter 30
Fuel hose 30
Engine idle speed 31
A warning 32
Evaporative emission control system e 33 only 32
Pair air supply system e 33 only 32
Throttle cable play 32
Throttle valve synchronization 32
Clutch 33
À warning 33
Awarning 34
Cooling system 34
Drive chain 36
Cautio 38
Warning 38
Steering 41
Exhaust pipe bolt 42
Front fork 42
Rear suspension 42
Chassis bolt and nut 43
Compression pressure check 45
Compression test procedure 45
Oil pressure check 46
Oil pressure test procedure 46
Engine 47
Engine components removable with engine in place 48
Engine removal 49
Engine removal and installation 49
Engine installation 58
Engine disassembly 63
Engine disassembly and reassembly 63
Engine reassembly 84
Cautiqn 89
A cautio 123
A 1 engine 128
Cam drive system description 128
The tl1000rw cam drive system consists of the crankshaft the primary drive gear the no cam drive idle gear sprocket the no cam drive idle gear shaft sprocket the cam chains the no cam drive idle gears sprockets and the camshafts this system allows the cam drive gear diameter is much smaller than a conventional cam drive sprocket system and the cam drive gears are smaller so that overall cylinder height can be reduced the primary drive gear and the cam drive gears use scissors gears to eliminate backlash and reduce mechanical noise 128
Cam timing table 132
Camshaft removal 133
Cylinder head removal 135
Camshaft cylinder head inspection and service 140
Awarning 148
Cylinder head installation 152
Camshaft installation 156
Cylinder piston 159
Cylinder piston removal 160
Cylinder piston inspection 161
Piston cylinder installation 164
Clutch 167
Clutch removal 168
Clutch inspection 170
Clutch installation 171
Clutch release cylinder 174
Water pump clutch cover 175
Water pump clutch cover removal 176
Water pump clutch cover inspection and service 177
Water pump clutch cover installation 179
Primary drive gear n0 cam drive idle gear shaft sprocket 181
Primary drive gear removal 182
No cam drive idle gear shaft sprocket removal 183
N0 cam drive idle gear sprocket and no cam drive idle gear shaft sprocket inspection 184
Primary drive gear inspection and service 184
Primary drive gear installation 185
No cam drive idle gear shaft sprocket installation 186
Starter system generator crankshaft position sensor 187
Starter torque limiter generator crankshaft position sensor removal 188
Starter torque limiter generator crankshaft position sensor inspection and service 190
Starter torque limiter generator crankshaft position sensor installation 193
Starter motor inspection and servicing 195
Starter motor installation 195
Starter motor removal 195
Gearshift linkage 197
Gearshift linkage removal 198
Gearshift linkage inspection and service 200
Gearshift linkage installation 202
Transmission crankshaft conrod removal 208
Transmission inspection and service 208
Engine 3h 6 213
Conrod crank pin bearing inspection and service 215
Conrod crankshaft inspection 215
Crankcase crankshaft bearing inspection and service 218
Crankshaft thrust clearance adjustment 222
Transmission crankshaft conrod installation 223
Engine lubrication system 225
Oil pump 226
Oil sump filter oil pressure regulator 228
Oil pressure switch oil cooler 231
Oil filter 232
Oil pressure 232
Piston cooling oil nozzle oil jet 232
Engine lubrication system chart 234
Engine lubrication system 235
Fl system and intake air system 236
Fuel injection system 236
Connector coupler 238
Precautions in servicing 238
Ecm various sensors 239
Electrical circuit inspection procedure 240
Using testers 243
Fl system technical features 244
Injection time injection volume 244
Compensation of injection time volume 245
Injection stop control 245
Fuel delivery system 246
Fuel pump 247
Fuel injector 248
Fuel pressure regulator 248
Fuel pump control system 249
Ecm fl control unit 250
A a a f a a a 251
A a h ii 251
Injection timing 251
Y y y y y y 1 v y y ol y v y y y y y 251
Sensors 252
Intake air system technical features 256
Intake air control valve 257
Operation 258
Fl system diagram 262
Self diagnosis function 264
User mode 264
Dealer mode 265
Fail safe function 267
Customer complaint analysis 268
Fl system trouble shooting 268
Self diagnosis reset procedure 269
Self diagnostic procedures 269
Malfunction code and defective condition 270
C11 cmp sensor circuit malfunction 272
C12 ckp sensor circuit malfunction 273
C13 iap sensor circuit malfunction 274
U i i i rrnx 275
C14 tp sensor circuit malfunction 276
C15 ect sensor circuit malfunction 278
I i i i i i i i i i i i i i i i i i 278
I i n i i i i i i i i i m 278
C21 iat sensor circuit malfunction 279
C22 ap sensor circuit malfunction 280
I i i i i i i m i i i i i n 281
Ijj l l l ini nnnl l __________ __________ 281
C23 to sensor circuit malfunction 282
C24 or c25 ignition system malfunction 283
C31 gear position gp switch circuit malfunction 283
C32 c33 c34 and c35 fuel injection malfunction 284
C41 fp relay circuit malfunction 285
C42 ig switch circuit malfunction 285
Awarning 286
Fuel system 286
Fuel tank lift up 286
Fuel tank removal 286
A warning 287
Fuel pressure inspection 287
Fuel tank installation 287
A warning 288
Fuel pump and fuel filter removal 288
Fuel pump inspection 288
Fuel pump relay inspection 288
A warning 290
Fuel mesh filter inspection and cleaning 290
Fuel pump and fuel filter installation 290
Construction 291
Fl system and intake air system 4 54 291
Throttle body 291
Air cleaner box removal 292
A warning 293
Air cleaner box installation 293
Throttle body removal 293
Throttle body disassembly 294
A warning 296
Throttle body cleaning 296
Inspection 297
Throttle body reassembly 297
Throttle body installation 302
Warning 303
Fast idle adjustment 305
Fuel injector inspection 305
Fuel injector installation 305
Fuel injector removal 305
Throttle valve synchronization 307
Fast idle cable adjustment 310
Throttle cable adjustment 310
Throttle lever gap adjustment 310
Throttle position sensor tps setting 310
Intake air system 311
Intake air system inspection 311
Vcsv inspection 311
Vtv inspection 311
Cautio 312
Intake air control valve actuator inspection 312
Vacuum damper inspection 312
Ckp sensor inspection 313
Ckp sensor removal installation 313
Cmp sensor inspection 313
Cmp sensor removal installation 313
Iap sensor inspection 313
Iap sensor removal installation 313
Sensors 313
Tp sensor inspection 313
Tp sensor removal installation 313
Ap sensor inspection 314
Ap sensor removal installation 314
Ect sensor inspection 314
Ect sensor removal installation 314
Iat sensor inspection 314
Iat sensor removal installation 314
To sensor inspection 314
To sensor removal installation 314
Fl system and intake air system 4 78 315
Throttle body reassembling information 315
Cooling system 317
Cooling system 320
Description 320
Construction 321
A caution 322
A warning 322
Engine coolant 322
A warning 323
Radiator and water hoses 323
Radiator removal 323
A caution 324
Awarning 324
Inspection 324
Cooling fan 326
Remounting 326
Removal 326
Inspection 327
Remounting 327
A warning 328
Cooling fan thermo switch 328
Removal 328
Inspection 329
Installation 329
Engine coolant temperature sensor 330
Removal 330
Warning 330
Inspection 331
Installation 331
A warning 332
Removal 332
Thermostat 332
Inspection 333
Installation 334
Water pump 334
Chassis 335
Removal 337
Remounting 340
Chassis 6 6 341
Construction 341
Front wheel 341
Inspection and disassembly 343
Removal 343
Reassembly and remounting 345
Cautio 346
Construction 347
Front fork 347
Removal and disassembly 348
Inspection 350
Reassembly and remounting 351
A warning 355
Suspension setting 355
Construction 356
Removal and disassembly 356
Steering 356
Inspection and disassembly 359
Reassembly and remounting 360
Steering tension adjustment 364
Construction 365
Rear wheel 365
Removal 367
Inspection and disassembly 368
Reassembly and remounting 369
Description 371
Rear suspension 371
Rotary damper operation 372
Construction 373
Rotary damper unit and spring unit removal 375
Rotary damper unit and spring unit inspection and disassembly 377
Rotary damper unit and spring unit reassembly and remounting 379
Final inspection and adjustment 381
Suspension setting 381
Rear swingarm removal 382
Rear swingarm inspection and disassembly 384
A caution 385
Rear swingarm reassembly and remounting 386
Final inspection and adjustment 388
A warning 389
Construction 389
Front brake 389
Brake fluid replacement 390
Brake pad replacement 390
A warning 391
Caliper removal and disassembly 391
Caliper inspection 392
Caliper reassembly and remounting 392
Brake disc inspection 393
Master cylinder removal and disassembly 394
Master cylinder inspection 395
Master cylinder reassembly and remounting 395
A warning 397
Construction 397
Rear brake 397
Brake fluid replacement 398
Brake pad replacement 398
A cautio 399
Awarning 399
Caliper removal and disassembly 399
Caliper inspection 400
Caliper reassembly and remounting 400
Master cylinder removal and disassembly 401
Master cylinder inspection 402
Master cylinder reassembly and remounting 402
Clutch master cylinder 403
Disassembly and reassembly 403
Removal 403
69 chassis 404
Note mark the tire with chalk to note the position of the tire on the rim and rotational direction of the tire 404
Remove the valve core from the valve stem and deflate the 404
The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead because of this we recommend using a tire changer which is also more efficient than tire levers for tire removal the following tools are required 404
Tire and wheel 404
Tire completely 404
Tire removal 404
Inspection 406
Ia caution 407
Tire installation 407
Awarning 408
Drive chain 409
Drive chain cutting 409
Awarning 410
Drive chain connecting 410
Electrical system 413
Cautions in servicing 414
Connector 414
Coupler 414
Semi conductor equipped part 414
Battery 415
Connecting battery 415
Using multi circuit tester 415
Wiring procedure 415
Location of electrical components 416
Charging system 418
Description 418
Troubleshooting 420
Inspection 421
Battery 423
Electrical system 7 10 423
Side stand ignition interlock system description 423
Starter system and side stand ignition interlock system 423
Starter system description 423
The starter system consists of the following components the starter motor starter relay clutch lever posi tion switch turn signal side stand relay side stand switch gear position switch starter button engine stop switch ignition switch and battery pressing the starter button on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery the starter motor draws about 80 amperes to start the engine 423
This side stand ignition interlock system prevents the motorcycle from being started with the side stand down the system is operated by an electric circuit provided between the battery and ignition coils 423
Troubleshooting 425
Starter motor inspection 426
Starter motor removal and disassembly 426
Starter motor reassembly 427
Starter relay inspection 428
Side stand ignition interlock system part inspection 429
Description 432
Ignition system 432
A caution 433
Electrical system 7 20 433
Engine can run over 10 600 r min without load even if the ignition cut off circuit is effective and it may cause engine damage do not run the engine without load over 10 600 r min at anytime 433
Front rear 433
Ignition timing map 433
Note the ignition cut off circuit is incorporated in this ecm to prevent over running engine if engine rpm reach es 10 600 r min this circuit cuts off the ignition primary current for all spark plugs 433
Wire color 433
Troubleshooting 434
Awarning 435
Inspection 435
Combination meter 439
Disassembly 439
Removal 439
27 electrical system 440
Inspection 440
Using the tester check the continuity between terminals in the following diagram if the continuity measured is incorrect re move and check the bulb if the bulb is failure install the new bulb and check the continu ity again if the bulb is correct replace the unit with a new one 440
_____ j 441
Headlight 445
Brake light taillight license light and turn signal light 446
Fuel pump relay 447
Starter relay 447
Turn signal side stand relay 447
Switches 448
Battery 449
Initial charging 449
Specifications 449
Servicing 450
Recharging operation 451
Servicing info 453
Servicing information 453
Fl system malfunction code and defective condition 454
Troubleshooting 454
Engine 456
Radiator cooling system 461
Chassis 462
Brakes 463
Electrical 464
Battery 465
For e 04 18 22 25 34 37 468
Servicing information 8 16 469
Sss 555 469
Мпз ммииса1 469
Тег 469
17 servicing information 470
For e 24 470
Wire harness cable and hose routing 472
Wire harness routing 472
Servicing information 8 20 473
21 servicing information 474
Cable routing 475
Servicing information 8 22 475
25 servicing information 478
Fuel tank drain hose routing 478
Section b b 479
Section c c 479
27 servicing information 480
Front brake hose routing 480
Rear brake hose routing 481
Servicing information 8 28 481
Clutch hose routing 482
Pair air supply system hose routing 483
Servicing information 8 36 489
Special tools 489
37 servicing information 490
Note when order the special tool please confirm whether it is available or not 491
Servicing information 8 38 491
Engine 492
Tightening torque 492
Chassis 493
Tightening torque chart 495
Camshaft cylinder head 496
Service data 496
Valve guide 496
Cylinder piston piston ring 497
Clutch 498
Conrod crankshaft 498
Oil pump 498
Thermostat radiator fan 499
Transmission drive chain 499
Fi sensors intake air control valve 500
Injector fuel pump fuel pressure regulator 500
Throttle body 500
Electrical 501
Wattage 501
Brake wheel 502
Suspension 503
Tire pressure 503
Fuel oil engine coolant 504
Emission control 505
Emission control information 505
Evaporative emission control system california model only 506
Fuel injection system 506
Canister 508
Evaporative emission control system inspection california model only 508
Tank pressure control valve 508
Warning 508
Emission control information 9 4 509
Pair air supply system diagram 509
Pair air supply system hose routing 510
Hoses and pipes 511
Pair air supply system inspection california model only 511
Pair control valve 511
Reed valve of pair control valve 511
Suzuki motor corporation 512

Suzuki TL1000R (1998-2002) [2/512] Tl 1000r

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