MOTORCYCLE

DATE: Aug. 18, 2005

PAGE: 1 OF 12

SUBJECT: SERVICE INFORMATION

APPLICABLE MODEL: DL1000K6
EFFECTIVE ENGINE OR FRAME NO.: E-02: JS1BS111200100911 –
E-19: JS1BS111100118455 –
E-24: JS1BS121300100359 –
E-03, 28, 33: JS1VT53A 62100001 –
REFERENCE: E-02, 03, 19, 24, 28, 33

This bulletin is to inform you of the service information for the DL1000K6 model. Please use
the following service manual along with the information contained in this bulletin for proper
servicing.

DL1000 SERVICE MANUAL (BOOK): 99500-39230-01E

99500-39231-01F
99500-39233-01G
99500-39230-01B
99500-39233-03E
DL1000 SERVICE MANUAL (CD-ROM): 99560-39233-01E

We hope that this information will be useful in your service activities.

CONTENTS
PAGE
SPECIFICATIONS...................................................................................... 2
SERVICE DATA ......................................................................................... 3

NOTE:
The specifications and service data are the same as the K5-MODEL.
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 295 mm (90.4 in)
Overall width........................................................................................ 910 mm (35.8 in)
Overall height ...................................................................................... 1 395 mm (54.9 in) ............. Low windshield position (STD)
1 420 mm (55.9 in) ............. Middle windshield position
1 450 mm (57.1 in) ............. High windshield position
Wheelbase .......................................................................................... 1 535 mm (60.4 in)
Ground clearance................................................................................ 165 mm (6.5 in)
Seat height .......................................................................................... 840 mm (33.1 in)
Dry mass ............................................................................................. 208 kg (458 lbs)
210 kg (462 lbs) .............. E33

ENGINE
Type..................................................................................................... 4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
Number of cylinders ............................................................................ 2
Bore..................................................................................................... 98.0 mm (3.858 in)
Stroke .................................................................................................. 66.0 mm (2.598 in)
Displacement ...................................................................................... 96 cm3 (60.8 cu. in)
Compression ratio ............................................................................... 11.3 : 1
Fuel system ......................................................................................... Fuel injection system
Air cleaner ........................................................................................... Non-woven fabric element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed............................................................................................ 1 200 ± 100 r/min

DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission ....................................................................................... 6-speed constant mesh
Gearshift pattern ................................................................................ 1-down, 5-up
Primary reduction ratio ........................................................................ 1.838 (57/31)
Gear ratios, Low ................................................................................ 3.000 (36/12)
2nd ................................................................................ 1.933 (29/15)
3rd ................................................................................. 1.500 (27/18)
4th ................................................................................. 1.227 (27/22)
5th ................................................................................. 1.086 (25/23)
Top................................................................................. 0.913 (21/23)
Final reduction ratio............................................................................. 2.411 (41/17)
Drive chain .......................................................................................... RK525 SMOZ7, 112 links

CHASSIS
Front suspension................................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front suspension stroke ...................................................................... 160 mm (6.3 in)
Rear wheel travel ................................................................................ 159 mm (6.3 in)
Caster.................................................................................................. 26° 30’
Trail...................................................................................................... 111 mm (4.4 in)
Steering angle ..................................................................................... 40° (right & left)
Turning radius...................................................................................... 2.7 m (8.86 ft)
Front brake .......................................................................................... Disc brake, twin
Rear brake........................................................................................... Disc brake
Front tire size....................................................................................... 110/80 R19M/C 59H, tubeless
Rear tire size ....................................................................................... 150/70 R17M/C 69H, tubeless

ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 4° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK CR8EK or DENSO U24ETR
Battery................................................................................................. 12 V 43.2 kC (12 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse............................................................................................. 30 A
Fuse .................................................................................................... 10/10/15/15/15/15 A
Headlight ............................................................................................. 12 V 60/55 W × 2 (H4 × 2)
Position/Parking light ........................................................................... 12 V 5 W × 2 ...................... Except E-03, 24, 28, 33
Brake light/Taillight .............................................................................. 12 V 21/5 W × 2
License plate light ............................................................................... 12 V 5 W
Turn signal /Hazard light...................................................................... 12 V 21 W
Speedometer light ............................................................................... LED
Tachometer light .................................................................................. LED
Turn signal indicator light..................................................................... LED
Neutral indicator light........................................................................... LED
High beam indicator light..................................................................... LED
Fuel injection warning light.................................................................. LED
(Coolant temperature , Oil pressure)

CAPACITIES
Fuel tank ............................................................................................. 22 L (5.81/4.84 US/Imp gal)
Engine oil, oil change......................................................................... 2 700 ml (2.9/2.4 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul............................................................................ 3 300 ml (3.5/2.9 US/Imp qt)
Coolant................................................................................................ 2.2 L (2.3/1.9 US/Imp qt)

–2–
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 36 —
(1.42)
EX. 33 —
(1.30)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem clear- IN. 0.010 – 0.037 —
ance (0.0004 – 0.0015)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve guide I.D. IN. & EX. 5.500 – 5.512 —
(0.2165 – 0.2170)
Valve stem O.D. IN. 5.475 – 5.490 —
(0.2156 – 0.2161)
EX. 5.455 – 5.470 —
(0.2148 – 0.2154)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve head thickness IN. & EX. — 0.5
(0.02)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length IN. & EX. — 39.6
(1.56)
Valve spring tension 197 – 227 N
IN. & EX. (20.1 – 23.1 kgf, 44.3 – 51.0 lbs) —
at length 35.6 mm (1.40 in)

–3–
CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD LIMIT
Cam height IN. 36.28 – 36.32 35.98
(1.428 – 1.430) (1.417)
EX. 35.68 – 35.72 35.38
(1.405 – 1.406) (1.393)
Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 0.150
(0.0007 – 0.0021) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.972 – 21.993 —
(0.8650 – 0.8659)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam drive idle gear/sprocket thrust 0.15 – 0.29 —
clearance (0.006 – 0.011)
Cylinder head distortion — 0.05
(0.002)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 000 – 1 400 kPa 800 kPa
(Automatic de-comp. actuated) (10 – 14 kgf/cm², 142 – 199 psi) (8 kgf/cm², 114 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm², 28 psi)
Piston to cylinder clearance 0.015 – 0.025 0.12
(0.0006 – 0.0010) (0.0047)
Cylinder bore 98.000 – 98.015 Nicks or
(3.8583 – 3.8589) Scratches
Piston diam. 97.980 – 97.995 97.880
(3.8575 – 3.8581) (3.8535)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion — 0.05
(0.002)
Piston ring free end gap 1st Approx. 8.8 (0.35) 7.0
(0.28)
2nd Approx. 10.1 (0.40) 8.1
(0.32)
Piston ring end gap 1st 0.15 – 0.35 0.5
(0.006 – 0.014) (0.02)
2nd RN 0.30 – 0.45 0.7
(0.012 – 0.018) (0.03)
Piston ring to groove clearance 1st — 0.18
(0.0071)
2nd — 0.15
(0.0059)

–4–
 ITEM STANDARD LIMIT
Piston ring groove width 0.93 – 0.95 —
(0.0366 – 0.0374)
1st
1.55 – 1.57 —
(0.0610 – 0.0618)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.51 – 2.53 —
(0.0988 – 0.0996)
Piston ring thickness 0.86 – 0.91 —
(0.034 – 0.036)
1st
1.38 – 1.40 —
(0.054 – 0.055)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore I.D. 22.002 – 22.008 22.030
(0.8662 – 0.8665) (0.8673)
Piston pin O.D. 21.992 – 22.000 21.980
(0.8658 – 0.8661) (0.8654)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 22.010 – 22.018 22.040
(0.8665 – 0.8668) (0.8677)
Conrod big end side clearance 0.17 – 0.32 0.50
(0.007 – 0.013) (0.020)
Conrod big end width 21.95 – 22.00 —
(0.864 – 0.866)
Crank pin width 44.17 – 44.22 —
(1.739 – 1.741)
Conrod big end oil clearance 0.040 – 0.064 0.080
(0.0016 – 0.0025) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance 0.002 – 0.029 0.080
(0.0008 – 0.0011) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft journal holder width 25.2 – 25.4
(0.99 – 1.00) —
Crankshaft journal width 25.50 – 25.55 —
(1.004 – 1.006)
Crankshaft runout — 0.05
(0.004)

–5–
OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 400 kPa (4.0 kgf/cm², 57 psi)
Below 700 kPa (7.0 kgf/cm², 100 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness No. 1 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
No. 2 and 3 3.72 – 3.88 3.42
(0.146 – 0.153) (0.135)
Drive plate claw width No.1 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
No. 2 and 3 13.90 – 14.00 13.10
(0.547 – 0.551) (0.516)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 61.5 – 62.5 59.4
(2.42 – 2.46) (2.34)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5512 – 0.5528)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5505)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)

THERMOSTAT + RADIATOR + FAN

ITEM STANDARD LIMIT
Thermostat valve opening temper- 86.5 – 89.5 °C —
ature (188 – 193 °F)
Thermostat valve lift Over 8 mm (0.31 in) at 100 °C (212 °F) —
Radiator cap valve opening pres- 110 kPa —
sure (1.1 kgf/cm², 15.6 psi)
Cooling fan ther- ON→OFF Approx. 105 °C (221 °F) —
moswitch operating ON→OFF Approx. 100 °C (212 °F) —
Engine coolant tem- 20 °C Approx. 2.45 kΩ —
perature sensor resis- (68 °F)
tance 40 °C
(104 °F) Approx. 1.148 kΩ —
60 °C Approx. 0.587 kΩ —
(140 °F)
80 °C Approx. 0.322 kΩ —
(176 °F)

–6–
DRIVE TRAIN Unit: mm (in) Expect ratio
ITEM STANDARD LIMIT
Primary reduction ratio 1.838 (57/31) —
Final reduction ratio 2.411 (41/17) —
Gear ratio Low 3.000 (36/12) —
2nd 1.933 (29/15) —
3rd 1.500 (27/18) —
4th 1.227 (27/22) —
5th 1.086 (25/23) —
Top 0.913 (21/23) —
Shift fork to groove clearance 0.1 – 0.3 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type RK525SMOZ7 —
Links 112 links, ENDLESS —
20-pitch length — 319.4
(12.6)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 25 —
(1.0)

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM SPECIFICATION NOTE
Injector resistance 12 – 18 Ω at 20 °C (68 °F)
Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)
for 1 minute at 300 kPa (3.0 kgf/cm², 43 psi)
Fuel pressure regulator operating Approx. 300 kPa (3.0 kgf/cm², 43 psi)
set pressure

–7–
FI-SENSORS
ITEM SPECIFICATION NOTE
CMP sensor output voltage More than 3.7 V
CKP sensor resistance 130 – 240 Ω
CKP sensor peak voltage More than 3.7 V (When cranking)
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.5 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
TP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor reisitance Approx. 2.45 kΩ at 20 °C (68 °F)
IAT sensor input volatage 4.5 – 5.5 V
IAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)
AP sensor input voltage 4.5 – 5.5 V
AP sensor output voltage Approx. 4.0 V at 760 mmHg (100 kPa)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage Approx. 0.4 – 1.4 V
GP switch voltage More than 1.0 V (From 1st to top)
Injector voltage Battery voltage
Ignition coil primary peak voltage More than 150 V (When cranking)
STP sensor input voltage 4.5 – 5.5 V
STP sensor resistance Closed Approx. 1.1 kΩ
Opened Approx. 4.3 kΩ
STP sensor output voltage Closed Approx. 1.1 V
Opened Approx. 4.3 V
STV actuator resistance 4.8 – 7.2 Ω
Heated oxygen sensor output volt- Less than 0.4 V at idle speed
age (After warming up) European
Heated oxygen sensor resistance 4 – 5 Ω at 23 °C (73.4 °F) markets
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

THROTTLE BODY
ITEM SPECIFICATION
ID No. 06G3 (For E-02, 19), 06G4 (For E-33), 06G5 (For E-03, 24, 28)
Bore size 45 mm
Fast idle r/min 1 500 – 2 100 r/min at 25 °C (77 °F)
Idle r/min 1 200 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 r/min
(0.08 – 0.16 in)

–8–
ELECTRICAL Unit: mm (in)
ITEM SPECIFICATION NOTE
Ignition timing 4° B.T.D.C. at 1 200 r/min
Firing order 1·2
Spark plug Type NGK: CR8EK
Denso: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Crankshaft position sensor resis- 130 – 240 Ω Bl – G
tance
Ignition coil resistance Primary 2–5Ω + tap – - tap
Secondary 24 – 37 kΩ + tap – Plug cap
Crankshaft position sensor peak More than 3.7 V When cranking
voltage
Ignition coil primary peak voltage More than 150 V When cranking
Generator coil resistance 0.2 – 0.5 Ω Y–Y
Generator Max. output Approx. 400 W at 5 000 r/min
Generator no-load voltage More than 75 V (AC) at 5 000 r/min
(When engine is cold)
Regulated voltage 14.0 – 15.5 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size HI 15 A
Headlight
LO 15 A
Turn signal 15 A
Ignition 10 A
Fan motor 15 A
Meter 10 A
Main 30 A

–9–
WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 24, 28, 33 Others
Headlight 12 V 60/55 W × 2 (H4) ←
Position/Parking light 12 V 5 W × 2
Brake light/Taillight 12 V 21/5 W × 2 ←
Turn signal light 12 V 21 W ←
License light 12 V 5 W ←
Speedometer light LED ←
Turn signal indicator light LED ←
High beam indicator light LED ←
Neutral indicator light LED ←
Oil pressure/Coolant temp./Fuel LED ←
injection warning

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 20 – 30 —
(0.8 – 1.2)
Brake disc thickness Front 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Rear 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Brake disc runout — 0.30
(Front & Rear) (0.012)
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6265)
Rear 14.000 – 14.043 —
(0.5512 – 0.5529)
Master cylinder piston diam. Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 13.957 – 13.984 —
(0.5495 – 0.5506)
Brake caliper cylinder bore Front 30.230 – 30.306 —
(1.1902 – 1.1931)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston diam. Front 30.150 – 30.200 —
(1.1870 – 1.1890)
Rear 38.098 – 38.148 —
(1.4999 – 1.5019)
Wheel rim runout Axial — 2.0
(Front & Rear) (0.08)
Radial — 2.0
(0.08)

– 10 –
 ITEM STANDARD LIMIT
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 19M/C × MT 2.50 —
Rear 17M/C × MT 4.00 —
Tire size Front 110/80R19M/C 59H —
Rear 150/70R17M/C 69H —
Tire type Front BRIDGESTONE: TW101 F —
Rear BRIDGESTONE: TW152 F —
Tire tread depth Front — 1.6
(0.06)
Rear — 2.0
(0.08)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT
Front fork stroke 160 —
(6.3)
Front fork spring free length 433.6 424
(17.07) (16.7)
Front fork oil level (without spring, 140.0 —
inner tube fully compressed) (5.51)
Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil
Front fork oil capacity (each leg) 496.0 ml
(16.76/17.46 US/lmp oz)
Front fork spring adjuster 3rd groove from top —
Rear shock absorber spring 2nd groove from bottom —
adjuster
Rear shock absorber damping Rebound 7/8 turn out from stiffest position —
force adjuster
Rear wheel travel 159 —
(6.3)
Swingarm pivot shaft runput — 0.3
(0.01)

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kgf/cm² psi kPa kgf/cm² psi
FRONT 250 2.50 36 250 2.50 36
REAR 250 2.50 36 280 2.80 41

– 11 –
FUEL + OIL + ENGINE COOLANT
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method. Gasoline containing MTBE
E-03, 28, 33
(Methyl Tertiary Butyl Ether), less than 10% etha-
nol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank 17 L
(4.5/3.7 US/lmp gal)
Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 2 700 ml
(2.9/2.4 US/lmp qt)
Filter change 2 900 ml
(3.1/2.6 US/lmp qt)
Overhaul 3 300 ml
(3.5/2.9 US/lmp qt)
Brake fluid type DOT 4
Engine coolant type Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the
ratio of 50:50.
Engien coolant Reserve Approx. 250 ml
tank side (0.3/0.2 US/lmp qt)
Engine side Approx. 1 950 ml
(2.1/1.7 US/lmp qt)

– 12 –