Download USE THIS MANUAL WITH: SV1000S/SV1000 SERVICE MANUAL

SV1000/S
USE THIS MANUAL WITH:
SV1000S/SV1000 SERVICE MANUAL (99500-39251-01E)
99501-39560-01E
SV1000K5/SK5
SV1000K5/SK5
FOREWORD
This manual describes service data, service specifications and servicing procedures which differ from those of the SV1000K4/SK4 (’04-model).
NOTE:
* Any differences between the SV1000K4/SK4 (’04-model) and SV1000K5/SK5
(’05-model) in specifications and service data are indicated with an asterisk mark (*).
* Please refer to the SV1000K4/SK4 Service Manual for details which are not given in this
manual.
CONTENTS
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COUNTRY AND AREA CODES.......................................................................... 2
SPECIFICATIONS (SV1000K5) .......................................................................... 3
SPECIFICATIONS (SV1000SK5) ........................................................................ 5
SERVICE DATA (SV1000K5).............................................................................. 7
SERVICE DATA (SV1000SK5) ...........................................................................16
CRANKCASE-CRANKSHAFT BEARING SELECTION .....................................25
FI SYSTEM WIRING DIAGRAM..........................................................................26
ECM TERMINAL (For K4-Model) .......................................................................27
ECM TERMINAL (For K5-Model) .......................................................................28
FAIL-SAFE FUNCTION .......................................................................................29
MALFUNCTION CODE AND DEFECTIVE CONDITION ....................................30
FI SYSTEM TROUBLESHOOTING.....................................................................32
FRONT FORK (For SV1000SK5)........................................................................36
FUEL LEVEL INDICATOR SWITCH INSPECTION ............................................37
WIRING HARNESS ROUTING (For SV1000K5) ................................................38
THROTTLE CABLE ROUTING (For SV1000K5) ...............................................40
THROTTLE BODY INSTALLATION/HOSE ROUTING ......................................41
REAR BRAKE HOSE ROUTING (For SV1000K5) .............................................42
REAR BRAKE HOSE ROUTING (For SV1000SK5) ..........................................43
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© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
1
2
SV1000K5/SK5
COUNTRY AND AREA CODES
The following codes stand for the applicable country (-ies) and area (-s).
CODE
COUNTRY or AREA
E-02
U.K.
E-03
E-28
E-33
U.S.A. (Except for California)
Canada
California (U.S.A.)
E-19
E.U.
E-24
Australia
EFFECTIVE FRAME NO.
SV1000K5 : JS1BX431200100001 –
SV1000SK5 : JS1BX412200100001 –
SV1000K5/SV1000SK5
: JS1VT54A 52100001 –
SV1000K5 : JS1BX431100100001
SV1000U2K5 : JS1BX521100100001
SV1000SK5 : JS1BX412100100001
SV1000S2K5 : JS1BX612100100001
SV1000K5 : JS1BX441300100001
SV1000SK5 : JS1BX442300100001
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–
–
–
–
–
–
SV1000K5/SK5
SPECIFICATIONS (SV1000K5)
DIMENSIONS AND DRY MASS
Overall length .....................................................................................
Overall width.......................................................................................
Overall height .....................................................................................
Wheelbase .........................................................................................
Ground clearance ...............................................................................
Seat height .........................................................................................
Dry mass ............................................................................................
2 080 mm (81.9 in)
785 mm (30.9 in)
1 080 mm (42.5 in)
1 445 mm (56.9 in)
150 mm ( 5.9 in)
800 mm (31.5 in)
187 kg (412 lbs) ................................. E-33
186 kg (410 lbs) ................................. Others
ENGINE
Type ....................................................................................................
Number of cylinders ...........................................................................
Bore....................................................................................................
Stroke .................................................................................................
Displacement......................................................................................
Compression ratio .............................................................................. *
Fuel system ........................................................................................
Air cleaner ..........................................................................................
Starter system ....................................................................................
Lubrication system .............................................................................
Idle speed ...........................................................................................
4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
2
98.0 mm (3.858 in)
66.0 mm (2.598 in)
996 cm3 (60.8 cu. in)
11.6 : 1
Fuel injection
Non-woven fabric element
Electric
Wet sump
1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Transmission.......................................................................................
Gearshift pattern ................................................................................
Primary reduction ratio .......................................................................
Gear ratios, Low ...............................................................................
2nd................................................................................
3rd ................................................................................
4th.................................................................................
5th.................................................................................
Top ................................................................................
Final reduction ratio ............................................................................
Drive chain..........................................................................................
Wet multi-plate type
6-speed constant mesh
1-down, 5-up
1.838 (57/31)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
2.352 (40/17)
RK50SMOZ1, 110 links
CHASSIS
Front suspension ................................................................................
Rear suspension ................................................................................
Front suspension stroke .....................................................................
Rear wheel travel................................................................................
Caster.................................................................................................
Trail .....................................................................................................
Steering angle ....................................................................................
Turning radius .....................................................................................
Front brake .........................................................................................
Rear brake..........................................................................................
Front tire size ......................................................................................
Rear tire size ......................................................................................
Telescopic, coil spring, oil damped
Link type, coil spring, oil damped
120 mm (4.7 in)
130 mm (5.1 in)
24.8°
107 mm (4.2 in)
32° (right & left)
3.0 m (9.84 ft)
Disc brake, twin
Disc brake
120/70ZR17M/C (58W), tubeless
180/55ZR17M/C (73W), tubeless
ELECTRICAL
Ignition type ........................................................................................
Ignition timing .....................................................................................
Spark plug ..........................................................................................
Battery ................................................................................................
Generator ...........................................................................................
Main fuse ............................................................................................
Fuse ...................................................................................................
Headlight ............................................................................................
Position light .......................................................................................
License plate light...............................................................................
Turn signal light ..................................................................................
Brake light/Tail light.............................................................................
Speedometer light ..............................................................................
Tachometer light .................................................................................
Fuel level indicator light ......................................................................
Turn signal indicator light....................................................................
Neutral indicator light..........................................................................
High beam indicator light ....................................................................
Oil pressure/Coolant temperature/Fuel injection warning light ...........
Electronic ignition (Transistorized)
5° B.T.D.C. at 1 200 r/min
NGK CR8EK or DENSO U24ETR
12 V 43.2 kC (12 Ah)/10 HR
Three-phase A.C. generator
30 A
10/10/10/15/10/15 A
12 V 60/55 W
12 V 5 W ................................................ E-02, 19
12 V 5 W
12 V 21 W
LED
LED
LED
LED
LED
LED
LED
LED
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3
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SV1000K5/SK5
CAPACITIES
Fuel tank .............................................................................................
Engine oil, oil change.........................................................................
with filter change ..............................................................
overhaul ...........................................................................
Coolant................................................................................................
16 L (4.2/3.5 US/Imp gal)................... E-33
17 L (4.5/3.7 US/Imp gal)................... Others
2 700 ml (2.9/2.4 US/Imp qt)
2 900 ml (3.1/2.6 US/Imp qt)
3 300 ml (3.5/2.9 US/Imp qt)
2.2 L (2.3/1.9 US/Imp qt)
These specifications are subject to change without notice.
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SV1000K5/SK5
SPECIFICATIONS (SV1000SK5)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 085 mm (82.1 in)
Overall width.......................................................................................
745 mm (29.3 in)
Overall height ..................................................................................... 1 170 mm (46.1 in)
Wheelbase ......................................................................................... 1 430 mm (56.3 in)
Ground clearance ...............................................................................
150 mm ( 5.9 in)
Seat height .........................................................................................
800 mm (31.5 in)
Dry mass ............................................................................................ * 187 kg (412 lbs) .................................. E-33
* 186 kg (410 lbs) .................................. Others
ENGINE
Type ....................................................................................................
Number of cylinders ...........................................................................
Bore....................................................................................................
Stroke .................................................................................................
Displacement......................................................................................
Compression ratio .............................................................................. *
Fuel system ........................................................................................
Air cleaner ..........................................................................................
Starter system ....................................................................................
Lubrication system .............................................................................
Idle speed ...........................................................................................
4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
2
98.0 mm (3.858 in)
66.0 mm (2.598 in)
996 cm3 (60.8 cu. in)
11.6 : 1
Fuel injection
Non-woven fabric element
Electric
Wet sump
1 200 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Transmission.......................................................................................
Gearshift pattern ................................................................................
Primary reduction ratio .......................................................................
Gear ratios, Low ...............................................................................
2nd................................................................................
3rd ................................................................................
4th.................................................................................
5th.................................................................................
Top ................................................................................
Final reduction ratio ............................................................................
Drive chain..........................................................................................
Wet multi-plate type
6-speed constant mesh
1-down, 5-up
1.838 (57/31)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
2.352 (40/17)
RK50SMOZ1, 108 links
CHASSIS
Front suspension ................................................................................
Rear suspension ................................................................................
Front suspension stroke .....................................................................
Rear wheel travel................................................................................
Caster.................................................................................................
Trail .....................................................................................................
Steering angle ....................................................................................
Turning radius .....................................................................................
Front brake .........................................................................................
Rear brake..........................................................................................
Front tire size ......................................................................................
Rear tire size ......................................................................................
Telescopic, coil spring, oil damped
Link type, coil spring, oil damped
115 mm (4.5 in)
130 mm (5.1 in)
24.5°
98 mm (3.9 in)
30° (right & left)
3.2 m (10.50 ft)
Disc brake, twin
Disc brake
120/70ZR17M/C (58W), tubeless
180/55ZR17M/C (73W), tubeless
ELECTRICAL
Ignition type ........................................................................................
Ignition timing .....................................................................................
Spark plug ..........................................................................................
Battery ................................................................................................
Generator ...........................................................................................
Main fuse ............................................................................................
Fuse ...................................................................................................
Headlight ............................................................................................
Position light .......................................................................................
License plate light...............................................................................
Turn signal light ..................................................................................
Brake light/Tail light.............................................................................
Speedometer light ..............................................................................
Tachometer light .................................................................................
Fuel level indicator light ......................................................................
Turn signal indicator light....................................................................
Neutral indicator light..........................................................................
High beam indicator light ....................................................................
Oil pressure/Coolant temperature/Fuel injection warning light ...........
Electronic ignition (Transistorized)
5° B.T.D.C. at 1 200 r/min
NGK CR8EK or DENSO U24ETR
12 V 43.2 kC (12 Ah)/10 HR
Three-phase A.C. generator
30 A
15/15/10/15/15/10 A
12 V 60/55 W × 2 (H4)
12 V 5 W × 2
12 V 5 W
12 V 21 W
LED
LED
LED
LED
LED
LED
LED
LED
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SV1000K5/SK5
CAPACITIES
Fuel tank .............................................................................................
Engine oil, oil change.........................................................................
with filter change ..............................................................
overhaul ...........................................................................
Coolant................................................................................................
16 L (4.2/3.5 US/Imp gal)................... E-33
17 L (4.5/3.7 US/Imp gal)................... Others
2 700 ml (2.9/2.4 US/Imp qt)
2 900 ml (3.1/2.6 US/Imp qt)
3 300 ml (3.5/2.9 US/Imp qt)
2.2 L (2.3/1.9 US/Imp qt)
These specifications are subject to change without notice.
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SV1000K5/SK5
7
SERVICE DATA (SV1000K5)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
STANDARD
36
(1.42)
33
(1.30)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.046
(0.0004 – 0.0018)
0.030 – 0.066
(0.0012 – 0.0026)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
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—
—
—
—
—
—
—
—
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
41.2
(1.62)
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
at length 35.6 mm (1.40 in)
IN. & EX.
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IN. & EX.
Valve spring tension
—
—
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
LIMIT
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
—
Unit: mm (in)
STANDARD
37.78 – 37.82
(1.487 – 1.489)
* 37.18 – 37.22
(1.464 – 1.465)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8650 – 0.8659)
LIMIT
37.48
(1.476)
* 36.88
(1.452)
0.150
(0.0059)
—
—
8
SV1000K5/SK5
ITEM
Camshaft runout
STANDARD
IN. & EX.
Cam drive idle gear/sprocket thrust
clearance
Cylinder head distortion
—
0.15 – 0.29
(0.006 – 0.011)
—
—
0.05
(0.002)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring end gap
(8.5 kgf/cm2, 121 psi)
—
(2 kgf/cm2, 28 psi)
* 850 kPa
200 kPa
0.05
(0.002)
7.0
(0.28)
8.1
(0.32)
0.7
(0.03)
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
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1st
Approx. 8.8 (0.35)
2nd
Approx. 10.1 (0.40)
1st
0.15
(0.006
0.30
(0.012
– 0.35
– 0.014)
– 0.45
– 0.018)
1st
—
2nd
—
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin O.D.
LIMIT
—
Piston ring groove width
Piston pin bore I.D.
STANDARD
* 1 050 – 1 450 kPa
(10.5 – 14.5 kgf/cm2, 149 – 206 psi)
0.12
(0.0047)
Nicks or
Scratches
2nd
Piston ring to groove clearance
Unit: mm (in)
0.015 – 0.025
(0.0006 – 0.0010)
98.000 – 98.015
(3.8583 – 3.8589)
97.980 – 97.995
(3.8575 – 3.8581)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
LIMIT
0.10
(0.004)
0.93 – 0.95
(0.0366 – 0.0374)
1.55 – 1.57
(0.0610 – 0.0618)
1.01 – 1.03
(0.0398 – 0.0406)
2.51 – 2.53
(0.0988 – 0.0996)
0.86 – 0.91
(0.034 – 0.036)
1.38 – 1.40
(0.054 – 0.055)
0.97 – 0.99
(0.038 – 0.039)
22.002 – 22.008
(0.8662 – 0.8665)
21.993 – 22.000
(0.8658 – 0.8661)
97.880
(3.8535)
—
—
—
—
—
—
—
22.030
(0.8673)
21.980
(0.8654)
SV1000K5/SK5
CONROD + CRANKSHAFT
Unit: mm (in)
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
STANDARD
22.010 – 22.018
(0.8665 – 0.8668)
0.17 – 0.32
(0.007 – 0.013)
21.95 – 22.00
(0.864 – 0.866)
44.17 – 44.22
(1.739 – 1.741)
0.040 – 0.064
(0.0016 – 0.0025)
44.976 – 45.000
(1.7707 – 1.7717)
* – 0.004 – 0.023
(– 0.0002 – 0.0009)
47.985 – 48.000
(1.8892 – 1.8898)
LIMIT
22.040
(0.8677)
0.50
(0.020)
—
0.05
(0.002)
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
CLUTCH
ITEM
Drive plate thickness
No. 1
No. 2 and 3
No. 1
No. 2 and 3
Driven plate distortion
Clutch spring free length
Clutch master cylinder bore
Clutch master cylinder piston diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
Clutch fluid type
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STANDARD
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
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Drive plate claw width
9
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
13.85 – 13.96
(0.545 – 0.550)
13.90 – 14.00
(0.547 – 0.551)
—
28.1
(1.11)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
DOT 4
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
LIMIT
—
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
0.10
(0.004)
26.7
(1.05)
—
—
—
—
—
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SV1000K5/SK5
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
STANDARD
86.5 – 89.5 °C
(188 – 193 °F)
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
LIMIT
110 kPa (1.1 kgf/cm2, 15.6 psi)
—
Approx. 105 °C (221 °F)
OFF → ON
Approx. 100 °C (212 °F)
ON → OFF
Engine coolant temperature sensor
20 °C
Approx. 2.45 kΩ
resistance
(68 °F)
40 °C
Approx. 1.15 kΩ
(104 °F)
60 °C
Approx. 0.58 kΩ
(140 °F)
80 °C
Approx. 0.32 kΩ
(176 °F)
Engine coolant type
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Engine coolant
Reservoir
Approx. 250 ml (0.3/0.2 US/lmp qt)
tank side
Engine
Approx. 1 950 ml (2.1/1.7 US/lmp qt)
side
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
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Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
Type
Links
20-link
length
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STANDARD
1.838 (57/31)
2.352 (40/17)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK50SMOZ1
110 links, ENDLESS
—
20
(0.8
55
(2.2
– 30
– 1.2)
– 65
– 2.6)
—
—
—
—
—
—
—
—
—
—
—
Unit: mm (in) Expect ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
—
SV1000K5/SK5
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
168 ml and more (5.7/5.9 US/lmp oz)
for 10 seconds at 300 kPa (3.0 kgf/cm2 , 43 psi)
NOTE
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
FI-SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage (F & R)
IAP sensor output voltage (F & R)
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
SPECIFICATION
130 – 240 Ω
5.0 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
200 V and more (When cranking)
4.5 – 5.5 V
Closed
Approx. 0.58 kΩ
Opened
Approx. 4.38 kΩ
Closed
Approx. 0.58 V at input voltage is 5.0 V
Opened Approx. 4.38 V at input voltage is 5.0 V
7 – 14 Ω
0.4 V and less at idle speed
0.6 V and more at 3 000 r/min
4 – 5 Ω at 23 °C (73.4 °F)
20 – 24 Ω at 20 °C (68 °F)
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STP sensor output voltage
STV actuator resistance
Heated oxygen sensor output voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
NOTE
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E-02, 19
E-02, 19
E-02, 19
11
12
SV1000K5/SK5
THROTTLE BODY
ITEM
SPECIFICATION
* 16G4 (For E-33), 16G3 (Others)
* 54 mm
1 900 – 2 500 r/min at 25 °C (77 °F)
1 200 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
ELECTRICAL
Unit: mm (in)
ITEM
Firing order
Spark plug
SPECIFICATION
1·2
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Crankshaft position sensor resistance
Ignition coil resistance
130 – 240 Ω
2.8 – 4.2 Ω
Secondary
24 – 36 kΩ
P
M
A
S
Crankshaft position sensor peak
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
HI
Headlight
LO
Fuel
Ignition
Turn signal
Fan motor
Main
E
L
Primary
NOTE
Bl – G
+ tap – - tap
+ tap –
Plug cap
5.0 V and more
When cranking
200 V and more
0.2 – 0.7 Ω
Approx. 400 W at 5 000 r/min
When cranking
Y–Y
75 V and more (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
10 A
10 A
10 A
15 A
10 A
15 A
30 A
SV1000K5/SK5
WATTAGE
13
Unit: W
ITEM
Headlight
SPECIFICATION
60
55
5
LED
21 × 4
LED
LED
LED
LED
LED
HI
LO
Position light (For E-02, 19)
Brake light/Taillight
Turn signal light
Speedometer/Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Fuel indicator light
Coolant temperature/Oil pressure/
FI indicator light
License light
LED
5
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
P
M
A
S
Front
Rear
Brake disc runout
(Front & Rear)
Master cylinder bore
—
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder
bore
Leading
Front
Trailing
Rear
Brake caliper piston
diam.
Leading
Front
Trailing
Rear
Brake fluid type
E
L
STANDARD
55 – 65
(2.17 – 2.56)
5.0 ± 0.2
(0.197 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
15.870
(0.6248
14.000
(0.5512
15.827
(0.6231
13.957
(0.5495
30.230
(1.1902
33.960
(1.3370
38.180
(1.5031
30.167
(1.1876
33.901
(1.3346
38.115
(1.5005
DOT 4
– 15.913
– 0.6265)
– 14.043
– 0.5529)
– 15.854
– 0.6242)
– 13.984
– 0.5506)
– 30.280
– 1.1921)
– 34.010
– 1.3389)
– 38.230
– 1.5051)
– 30.200
– 1.1890)
– 33.934
– 1.3360)
– 38.148
– 1.5019)
Unit: mm (in)
LIMIT
—
4.5
(0.18)
4.5
(0.18)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
—
—
14
SV1000K5/SK5
ITEM
Wheel rim runout
(Front & Rear)
STANDARD
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
Front
Rear
Front
Rear
17M/C × MT 3.50
17M/C × MT 5.50
120/70 ZR17M/C (58W), tubeless
180/55 ZR17M/C (73W), tubeless
MICHELIN: PILOT ROAD B
MICHELIN: PILOT ROAD B
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
(without spring, inner tube fully
compressed)
Front fork oil type
Front fork oil capacity (each leg)
P
M
A
S
Front fork spring adjuster
Front fork damping force adjuster
Rear shock absorber spring pre-set
length
Rear shock absorber damping
force adjuster
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
120
(4.7)
305
(12.0)
E
L
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
LIMIT
—
298
(11.7)
147
(5.8)
—
SUZUKI FORK OIL L01 or an equivalent fork oil
508 ml
(17.2/17.9 US/lmp oz)
7th groove from top
1 and 1/4 turns out
Rebound
from stiffest position
Compres1 turn out from stiffest position
sion
—
—
202
(8.0)
—
Rebound
Compression
3/4 turn out from stiffest position
1 and 3/4 turns out
from stiffest position
130
(5.1)
—
—
—
—
—
—
—
0.3
(0.01)
SV1000K5/SK5
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
250
250
SOLO RIDING
kgf/cm2
2.50
2.50
psi
36
36
kPa
250
290
DUAL RIDING
kgf/cm2
2.50
2.90
psi
36
42
FUEL + OIL
ITEM
Fuel type
Fuel tank
Engine oil type
Engine oil capacity
SPECIFICATION
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
(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
16 L (4.2/3.5 US/lmp gal)
17 L (4.5/3.7 US/lmp gal)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
2 700 ml
Change
(2.9/2.4 US/lmp qt)
2 900 ml
Filter change
(3.1/2.6 US/lmp qt)
3 300 ml
Overhaul
(3.5/2.9 US/lmp qt)
P
M
A
S
E
L
NOTE
E-33
The others
E-33
The others
15
16
SV1000K5/SK5
SERVICE DATA (SV1000SK5)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
Valve spring tension
STANDARD
36
(1.42)
33
(1.30)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.046
(0.0004 – 0.0018)
0.030 – 0.066
(0.0012 – 0.0026)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
E
L
—
—
—
—
—
—
—
—
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
41.2
(1.62)
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
at length 35.6 mm (1.40 in)
P
M
A
S
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
LIMIT
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
—
Unit: mm (in)
STANDARD
37.78 – 37.82
(1.487 – 1.489)
* 37.18 – 37.22
(1.464 – 1.465)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8650 – 0.8659)
LIMIT
37.48
(1.476)
* 36.88
(1.452)
0.150
(0.0059)
—
—
SV1000K5/SK5
ITEM
Camshaft runout
STANDARD
IN. & EX.
Cam drive idle gear/sprocket thrust
clearance
Cylinder head distortion
—
ITEM
Compression pressure
(Automatic de-comp. actuated)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
—
0.05
(0.002)
Piston ring end gap
LIMIT
* 850 kPa
(8.5 kgf/cm2, 121 psi)
—
(2 kgf/cm 2, 28 psi)
200 kPa
0.12
(0.0047)
Nicks or
Scratches
—
0.05
(0.002)
7.0
(0.28)
8.1
(0.32)
0.7
(0.03)
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
E
L
1st
Approx. 8.8 (0.35)
2nd
Approx. 10.1 (0.40)
1st
2nd
0.15 – 0.35
(0.006 – 0.014)
0.30 – 0.45
(0.012 – 0.018)
1st
—
2nd
—
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin O.D.
STANDARD
* 1 050 – 1 450 kPa
(10.5 – 14.5 kgf/cm2 , 149 – 206 psi)
P
M
A
S
Piston ring to groove clearance
Piston pin bore I.D.
Unit: mm (in)
0.015 – 0.025
(0.0006 – 0.0010)
98.000 – 98.015
(3.8583 – 3.8589)
97.980 – 97.995
(3.8575 – 3.8581)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
LIMIT
0.10
(0.004)
0.15 – 0.29
(0.006 – 0.011)
CYLINDER + PISTON + PISTON RING
17
0.93 – 0.95
(0.0366 – 0.0374)
1.55 – 1.57
(0.0610 – 0.0618)
1.01 – 1.03
(0.0398 – 0.0406)
2.51 – 2.53
(0.0988 – 0.0996)
0.86 – 0.91
(0.034 – 0.036)
1.38 – 1.40
(0.054 – 0.055)
0.97 – 0.99
(0.038 – 0.039)
22.002 – 22.008
(0.8662 – 0.8665)
21.993 – 22.000
(0.8658 – 0.8661)
97.880
(3.8535)
—
—
—
—
—
—
—
22.030
(0.8673)
21.980
(0.8654)
18
SV1000K5/SK5
CONROD + CRANKSHAFT
Unit: mm (in)
ITEM
Conrod small end I.D.
STANDARD
22.010 – 22.018
(0.8665 – 0.8668)
0.17 – 0.32
(0.007 – 0.013)
21.95 – 22.00
(0.864 – 0.866)
44.17 – 44.22
(1.739 – 1.741)
0.040 – 0.064
(0.0016 – 0.0025)
44.976 – 45.000
(1.7707 – 1.7717)
* – 0.004 – 0.023
(– 0.0002 – 0.0009)
47.985 – 48.000
(1.8892 – 1.8898)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
CLUTCH
ITEM
Drive plate thickness
P
M
A
S
No. 1
No. 2 and 3
Drive plate claw width
No. 1
No. 2 and 3
Driven plate distortion
Clutch spring free length
Clutch master cylinder bore
Clutch master cylinder piston diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
Clutch fluid type
E
L
STANDARD
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
13.85 – 13.96
(0.545 – 0.550)
13.90 – 14.00
(0.547 – 0.551)
—
28.1
(1.11)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
DOT 4
LIMIT
22.040
(0.8677)
0.50
(0.020)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
0.05
(0.002)
LIMIT
—
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
0.10
(0.004)
26.7
(1.05)
—
—
—
—
—
SV1000K5/SK5
19
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
STANDARD
86.5 – 89.5 °C
(188 – 193 °F)
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
LIMIT
110 kPa (1.1 kgf/cm2, 15.6 psi)
—
OFF → ON
Approx. 105 °C (221 °F)
Approx. 100 °C (212 °F)
ON → OFF
Engine coolant temperature sensor
20 °C
Approx. 2.45 kΩ
resistance
(68 °F)
40 °C
Approx. 1.15 kΩ
(104 °F)
60 °C
Approx. 0.58 kΩ
(140 °F)
80 °C
Approx. 0.32 kΩ
(176 °F)
Engine coolant type
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Engine coolant
Reservoir
Approx. 250 ml (0.3/0.2 US/lmp qt)
tank side
Engine
Approx. 1 950 ml (2.1/1.7 US/lmp qt)
side
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio
P
M
A
S
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
Type
Links
20-link
length
E
L
—
—
—
—
—
—
—
—
—
—
Unit: mm (in) Expect ratio
STANDARD
1.838 (57/31)
2.352 (40/17)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK50SMOZ1
108 links, ENDLESS
—
20
(0.8
55
(2.2
—
– 30
– 1.2)
– 65
– 2.6)
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
—
20
SV1000K5/SK5
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
Fuel pump discharge amount
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
168 ml and more (5.7/5.9 US/lmp oz)
for 10 seconds at 300 kPa (3.0 kgf/cm2, 43 psi)
Fuel pressure regulator operating
set pressure
NOTE
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
FI-SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage (F & R)
IAP sensor output voltage (F & R)
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
SPECIFICATION
130 – 240 Ω
5.0 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
200 V and more (When cranking)
4.5 – 5.5 V
Closed
Approx. 0.58 kΩ
Opened
Approx. 4.38 kΩ
Closed
Approx. 0.58 V at input voltage is 5.0 V
Opened Approx. 4.38 V at input voltage is 5.0 V
7 – 14 Ω
0.4 V and less at idle speed
0.6 V and more at 3 000 r/min
4 – 5 Ω at 23 °C (73.4 °F)
20 – 24 Ω at 20 °C (68 °F)
P
M
A
S
STP sensor output voltage
STV actuator resistance
Heated oxygen sensor output voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
NOTE
E
L
E-02, 19
E-02, 19
E-02, 19
SV1000K5/SK5
21
THROTTLE BODY
ITEM
SPECIFICATION
* 16G4 (For E-33), 16G3 (For others)
* 54 mm
1 900 – 2 500 r/min at 25 °C (77 °F)
1 200 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
ELECTRICAL
Unit: mm (in)
ITEM
Firing order
Spark plug
SPECIFICATION
1·2
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Crankshaft position sensor resistance
Ignition coil resistance
Primary
Secondary
P
M
A
S
Crankshaft position sensor peak
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
HI
Headlight
LO
Fuel
Ignition
Turn signal
Fan motor
Main
E
L
130 – 240 Ω
2.8 – 4.2 Ω
24 – 36 kΩ
NOTE
Bl – G
+ tap – - tap
+ tap – Plug cap
5.0 V and more
When cranking
200 V and more
0.2 – 0.7 Ω
Approx. 400 W at 5 000 r/min
When cranking
Y–Y
75 V and more (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
15 A
15 A
10 A
15 A
10 A
15 A
30 A
22
SV1000K5/SK5
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
60 × 2
55 × 2
5×2
LED
21 × 4
LED
LED
LED
LED
LED
HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer/Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Fuel indicator light
Coolant temperature/oil pressure/
FI indicator light
License light
LED
5
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
P
M
A
S
Front
Rear
Brake disc runout
(Front & Rear)
Front
Rear
Master cylinder piston diam.
Front
Rear
Leading
Front
Trailing
Rear
Brake caliper piston
diam.
Leading
Front
Trailing
Rear
Brake fluid type
15.870
(0.6248
14.000
(0.5512
15.827
(0.6231
13.957
(0.5495
30.230
(1.1902
33.960
(1.3370
38.180
(1.5031
30.167
(1.1876
33.901
(1.3346
38.115
(1.5005
DOT 4
LIMIT
—
0.2
0.008)
0.2
0.008)
4.5
(0.18)
4.5
(0.18)
0.30
(0.012)
– 15.913
– 0.6265)
– 14.043
– 0.5529)
– 15.854
– 0.6242)
– 13.984
– 0.5506)
– 30.280
– 1.1921)
– 34.010
– 1.3389)
– 38.230
– 1.5051)
– 30.200
– 1.1890)
– 33.934
– 1.3360)
– 38.148
– 1.5019)
—
—
Master cylinder bore
Brake caliper cylinder
bore
E
L
STANDARD
55 – 65
(2.17 – 2.56)
5.0 ±
(0.197 ±
5.0 ±
(0.197 ±
Unit: mm (in)
—
—
—
—
—
—
—
—
—
—
SV1000K5/SK5
ITEM
Wheel rim runout
(Front & Rear)
STANDARD
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
Front
Rear
Front
Rear
17 × MT 3.50, 17M/C × MT 3.50
17 × MT 5.50, 17M/C × MT 5.50
120/70 ZR17M/C (58W), tubeless
180/55 ZR17M/C (73W), tubeless
MICHELIN: PILOT SPORT E
MICHELIN: PILOT SPORT L
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
P
M
A
S
Front fork spring free length
Front fork oil level
(without spring, inner tube fully
compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Front fork damping force adjuster
Rear shock absorber spring pre-set
length
Rear shock absorber damping
force adjuster
Rear wheel travel
Swingarm pivot shaft runout
E
L
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
STANDARD
115
(4.5)
* 260.2
(10.24)
LIMIT
* 140
(5.5)
—
—
* 254
(10.0)
SUZUKI FORK OIL L01 or an equivalent fork oil
* 565 ml
(19.1/19.9 US/lmp oz)
6th groove from top
* 1 and 1/4 turn out
Rebound
from stiffest position
Compres1 turn out from stiffest position
sion
—
199.3
(7.85)
—
Rebound
Compression
3/4 turn out from stiffest position
2 and 1/4 turns out
from stiffest position
130
(5.1)
—
23
—
—
—
—
—
—
—
0.3
(0.01)
24
SV1000K5/SK5
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
250
250
SOLO RIDING
kgf/cm2
2.50
2.50
psi
36
36
kPa
250
290
DUAL RIDING
kgf/cm2
2.50
2.90
psi
36
42
FUEL + OIL
ITEM
Fuel type
Fuel tank
Engine oil type
Engine oil capacity
SPECIFICATION
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
(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
16 L (4.2/3.5 US/lmp gal)
17 L (4.5/3.7 US/lmp gal)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
2 700 ml
Change
(2.9/2.4 US/lmp qt)
2 900 ml
Filter change
(3.1/2.6 US/lmp qt)
3 300 ml
Overhaul
(3.5/2.9 US/lmp qt)
P
M
A
S
E
L
NOTE
E-03, 28, 33
The others
E-33
The others
SV1000K5/SK5
CRANKCASE-CRANKSHAFT BEARING SELECTION
Select the specified bearings from the crankcase bore I.D. code.
The crankcase bore I.D. code A “A”, “B” or “C”, is stamped on
the inside of each crankcase half.
Bearing selection table
I.D. code A
A
B
C
I.D. specification
52.000 – 52.006 mm
(2.0472 – 2.0475 in)
52.006 – 52.012 mm
(2.0475 – 2.0477 in)
52.012 – 52.018 mm
(2.0477 – 2.0479 in)
Bearing
Green
Black
Brown
Bearing thickness
Color (Part No.)
Green
(12229-16G00-0A0)
Black
(12229-16G00-0B0)
Brown
(12229-16G00-0C0)
!
Color code
Thickness
1.999 – 2.002 mm
(0.0787 – 0.0788 in)
2.002 – 2.005 mm
(0.0788 – 0.0789 in)
2.005 – 2.008 mm
(0.0789 – 0.0791 in)
P
M
A
S
Bearing must be replaced as a set.
E
L
25
26
SV1000K5/SK5
P
M
A
S
E
L
(For E-02, 19)
FI SYSTEM WIRING DIAGRAM
SV1000K5/SK5
27
ECM TERMINAL (For K4-Model)
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
TERMINAL
NO.
Front cylinder ignition coil (IG1)
M
Rear cylinder ignition coil (IG2)
N
Ground (E3)
O
Serial data for tachometer (TACO)
P
Front cylinder fuel injector (#1)
Q
Rear cylinder fuel injector (#2)
R
PAIR control solenoid valve (PAIR)
S
HO2 sensor heater (HO2) For E-02, 19
T
Power source for back-up (B+2)
U
Power source for sensors (VCC)
V
—
W
CMP sensor signal (CMPS)
X
ECM ground (E1)
Y
IAT sensor signal (IAT)
Z
Power source (B+1)
[
IAP sensor signal (IAPS)
\
ATM pressure sensor signal (APS)
]
Clutch lever position switch (CLP)
^
TP sensor signal (TP)
a
Actuator motor (+)
b
Starter switch (STA)
c
Actuator motor (–)
d
CIRCUIT
P
M
A
S
CIRCUIT
HO2 control selector (EXS) For E-02, 19
HO2 sensor signal (HO2S) For E-02, 19
—
CKP sensor signal (CKP+)
—
Power source for fuel injector (VM)
—
CKP sensor signal (CKP–)
GP switch signal (GP)
Fuel pump relay (FP Relay)
Ignition switch signal (AT)
Sensor ground (E2)
Ground (E1)
ECT sensor signal (ECT)
Serial data for speedometer (TECH)
—
—
Neutral switch (NT)
TO sensor signal (TOS)
—
—
STP sensor signal (STP)
E
L
28
SV1000K5/SK5
ECM TERMINAL (For K5-Model)
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
TERMINAL
NO.
—
H
—
I
Actuator motor (–)
J
Actuator motor (+)
K
STP sensor signal (STP)
L
Serial data for speedometer (TECH)
M
Blank
N
TP sensor signal (TP)
O
IAP sensor signal (Front) (IAPS)
P
ECT sensor signal (ECT)
Q
Power source for sensor (VCC)
R
HO2 sensor signal (HO2S) For E-02, 19
S
Blank
T
CKP sensor signal (CKP+)
U
Ignition switch signal (AT)
V
Power source for back-up (B+2)
W
Power source (B+1)
X
TERMINAL
NO.
Y
Z
[
\
]
^
a
b
c
TERMINAL
NO.
HO2 sensor heater (HO2, H) For E-02, 19
d
Blank
e
Serial data for tachometer (TACO)
f
Fuel pump relay (FP Relay)
g
Blank
h
PAIR control solenoid valve (PAIR)
i
Rear cylinder fuel injector (#2)
j
Front cylinder fuel injector (#1)
k
Front cylinder ignition coil (IG1)
l
CIRCUIT
CIRCUIT
—
—
—
Blank
TO sensor signal (TOS)
GP switch signal (GP)
Blank
Blank
IAP sensor signal (Rear) (IAPS)
IAT sensor signal (IAT)
Blank
Sensor ground (E2)
Blank
CKP sensor signal (CKP–)
—
Power source for fuel injector (VM)
ECM ground (E1)
P
M
A
S
CIRCUIT
E
L
CIRCUIT
—
HO2 control selector (EXS) For E-02, 19
—
Neutral switch (NT)
Clutch lever position switch (CLP)
Starter switch (STA)
Ground (E3)
Ground (E1)
Rear cylinder ignition coil (IG2)
SV1000K5/SK5
29
FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
ITEM
FAIL-SAFE MODE
Intake air pressure sensor
(Front & Rear)
Throttle position sensor
Intake air pressure is fixed to
760 mmHg.
TPS opening value is fixed to full
open position.
Engine coolant temp. sensor Engine coolant temperature value is
fixed to 80 °C.
Intake air temperature sensor Intake air temperature value is fixed
to 40 °C.
Ignition signal #1 (IG coil #1) #1 Ignition-off and #1 Fuel-cut
Ignition signal #2 (IG coil #2) #2 Ignition-off and #2 Fuel-cut
Injection signal #1
#1 Fuel-cut
Injection signal #2
#2 Fuel-cut
P
M
A
S
HO2 sensor (For E-02, 19)
Secondary throttle valve
actuator
Secondary throttle position
sensor
Gear position signal
PAIR control solenoid valve
STARTING
ABILITY
RUNNING
ABILITY
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
#2 cylinder can
“YES”
#1 cylinder can
“YES”
#2 cylinder can
“YES”
#1 cylinder can
E
L
Feedback compensation is inhibited.
(Air/fuel ratio is fixed to normal.)
Secondary throttle valve is fixed in
any position.
Secondary throttle valve is fixed in
full close position.
Gear position signal is fixed to 6th
gear.
O2 feedback control is stopped and
PAIR valve is fixed to open position.
“YES”
run.
“YES”
run.
“YES”
run.
“YES”
run.
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
“YES”
The engine can start and can run even if the above signal is not received from each sensor. But, the engine
running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.
30
SV1000K5/SK5
MALFUNCTION CODE AND DEFECTIVE CONDITION
MALFUNCTION
DETECTED ITEM
CODE
C00
NO FAULT
Crankshaft position
sensor
C12
Intake air pressure
sensor (Front)
C13
C14
C15
Throttle position sensor
Engine coolant temperature sensor
P
M
A
S
Intake air pressure
sensor (Rear)
C17
C21
Intake air temperature
sensor
Tip over sensor
C23
Ignition signal
C24 or C25
DETECTED FAILURE CONDITION
CHECK FOR
——————
The signal does not reach ECM for more than 2 sec. after
receiving the starter signal.
The crankshaft position sensor wiring and mechanical parts
(Crankshaft position sensor, wiring/coupler connection)
When incorrect vacuum hose and/or lead wire coupler connection, C13 is indicated.
The sensor should produce following voltage.
(0.50 V
sensor voltage < 4.85 V)
Without the above range, C13 is indicated.
Intake air pressure sensor, wiring/coupler connection
The sensor should produce following voltage.
(0.20 V
sensor voltage < 4.80 V)
Without the above range, C14 is indicated.
Throttle position sensor, wiring/coupler connection
The sensor voltage should be the following.
(0.15 V
sensor voltage < 4.85 V)
Without the above range, C15 is indicated.
Engine coolant temperature sensor, wiring/coupler connection
When incorrect vacuum hose and/or lead wire coupler connection, C17 is indicated.
The sensor should produce following voltage.
(0.50 V
sensor voltage < 4.85 V)
Without the above range, C17 is indicated.
Intake air pressure sensor, wiring/coupler connection
The sensor voltage should be the following.
(0.15 V
sensor voltage < 4.85 V)
Without the above range, C21 is indicated.
Intake air temperature sensor, wiring/coupler connection
The sensor voltage should be the following for more than 2 sec.
after ignition switch turns ON.
(0.20 V
sensor voltage < 4.80 V)
Without the above value, C23 is indicated.
Tip over sensor, wiring/coupler connection
Crankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code
C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery
E
L
SV1000K5/SK5
Secondary throttle
valve actuator
C28
C29
C31
C32 or C33
C41
C42
C44
C49
31
When no actuator control signal is supplied from the ECM,
communication signal does not reatch ECM or operation voltage does not reach STVA motor, C28 is indicated. STVA can
not operate.
STVA lead wire/coupler, STVA
The sensor should produce following voltage.
Secondary throttle
valve position sensor
(0.10 V
sensor voltage < 4.90 V)
Without the above range, C29 is indicated.
Secondary throttle position sensor, wiring/coupler connection
Gear position signal
Gear position signal voltage should be higher than the following
for more than 2 seconds.
(Gear position switch voltage
0.6 V)
Without the above value, C31 is indicated.
Gear position sensor, wiring/coupler connection, gearshift cam,
etc.
Fuel injector
Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted
continuous by 4 times or more. In this case, the code C32 or
C33 is indicated.
Injector, wiring/coupler connection, power supply to the injector
Fuel pump relay
No voltage is applied to fuel pump although fuel pump relay is
turned ON, or voltage is applied to fuel pump although fuel
pump relay is turned OFF.
Fuel pump relay, connecting lead, power source to fuel pump
relay
Ignition switch
Ignition switch signal is not input in the ECM.
Ignition switch, lead wire/coupler
Heated oxygen sensor During O2 feedback control, O2 sensor voltage is higher or
(HO2S) [For E-02, 19] lower than the specification.
No signal is detected during engine operation or no electrical
power is supplied from the battery.
HO2S lead wire/coupler connection
Battery voltage supply to the HO2S
PAIR control solenoid When no operating voltage is supplied from the ECM, C49 is
valve (PAIR valve)
indicated. PAIR valve can not operate.
PAIR valve lead wire/coupler
P
M
A
S
E
L
32
SV1000K5/SK5
FI SYSTEM TROUBLESHOOTING
• Due to change from model K5, the connecting section of ECM wiring harness has also been modified as
shown in page 28.
• On model K5, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal are located as shown below.
NOTE:
To measure voltage, resistance or continuity of sensors, the terminals on the wiring harness side should be
used with the wiring harness coupler pulled free from ECM.
“C12” CKP SENSOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)
P
M
A
S
E
L
“C13” or “C17” IAP SENSOR CIRCUIT MALFUNCTION
3
ECM coupler (Wiring harness side)
“C14” TP SENSOR CIRCUIT MALFUNCTION
3
ECM coupler (Wiring harness side)
SV1000K5/SK5
“C15” ECT SENSOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)
“C21” IAT SENSOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)
P
M
A
S
E
L
“C23” TO SENSOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)
“C28” STV ACTUATOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)
33
34
SV1000K5/SK5
“C29” STP SENSOR CIRCUIT MALFUNCTION
3
ECM coupler (Wiring harness side)
“C31” GEAR PSOTION (GP) SWITCH CIRCUIT MALFUNCTION
ECM coupler (Wiring harness side)
P
M
A
S
E
L
“C32” or “C33” FUEL INJECTOR CIRCUIT MALFUNCTION
ECM coupler (Wiring harness side)
“C41” FP RELAY CIRCUIT MALFUNCTION
1
ECM coupler (Wiring harness side)
SV1000K5/SK5
“C44” HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (For E-02, 19)
3
ECM coupler (Wiring harness side)
“C49” PAIR CONTROL SOLENOID VALVE
2
ECM coupler (Wiring harness side)
P
M
A
S
E
L
35
36
SV1000K5/SK5
FRONT FORK (For SV1000SK5)
O-ring
Washer
! Spacer
" Spring
# Inner rod/Damper rod
(Cartridge)
$ Inner tube
% Protector
& Dust seal
' Oil seal stopper ring
Oil seal
) Oil seal retainer
* Guide metal
+ Slide metal
, Oil lock piece
- Outer tube
. Gasket
) Front fork cap bolt
* Inner rod lock nut
+ Front axle pinch bolt
, Damper rod bolt
(
ITEM
)
*
+
,
N·m
kgf-m
lb-ft
23
2.3
16.5
15
1.5
11.5
23
2.3
16.5
23
2.3
16.5
P
M
A
S
E
L
FRONT FORK SPRING
• When installing the front fork spring, the close pitch side to the
bottom of the front fork.
Bottom
SV1000K5/SK5
37
FUEL LEVEL INDICATOR SWITCH INSPECTION
• Remove and disassemble the fuel pump assembly.
Connect 12 V battery and test bulb (12 V, 3.4 W) to the fuel level
indicator switch as shown in the right illustrations. The bulb
should come on after several seconds if the switch is in good
condition.
When the switch is immersed in kerosine under the above condition, the bulb should go out. If the bulb remains lit, replace the
unit with a new one.
!
* When the light turns off, immediately pick up the
switch from kerosene.
* After the check has been completed, wash the switch
with gasoline.
P
M
A
S
ON
ON
Battery
Test
bulb
Test
bulb
OFF
OFF
Battery
Test
bulb
E
L
Kerosine
Battery
Test
bulb
Kerosine
Battery
38
SV1000K5/SK5
WIRING HARNESS ROUTING (For SV1000K5)
Generator lead
UPPER
Clamp
Wiring harness
Generator
Wiring harness
Set the coupler
center of the frame.
Ignition coil
Set the speed sensor
coupler under the
clutch hose.
P
M
A
S
Throttle cables
Wiring harness
Handle switch (L)
Side stand switch
Clamp
Clutch hose
E
L
Generator
Side stand switch
Speed sensor
Clamp
Cable guide
Clamp
Clamp
Handle switch (R)
Ignition switch
Clamp the lead wire
under the frame.
Starter motor
Battery
-
Set “ ” mark
exhaust side.
Ignition coil
Clamp
HO2 sensor (For E-02, 19)
SV1000K5/SK5
39
Clamp
Wiring harness
Neutral switch
Clamp the harness without
contact to the bracket.
Horn
Set the connector and
harness between the
frame and reservoir tank.
Don’t slacken.
Set surely.
P
M
A
S
Set “ ” mark exhaust side.
Taping clamp
Clamp
Harness
Rear turn signal light (L)
Licence lamp
E
L
Set the coupler inside triangle area
between the frame and fender.
Set the high tension cord rear side
as much as possible without contact
with the fuel tank.
Set the harness of the handle
inside of each hoses.
Inside of the head light
Turn signal (RH, LH)
Speedometer wire
Wiring harness
40
SV1000K5/SK5
THROTTLE CABLE ROUTING (For SV1000K5)
Throttle cable No. 1
Brake hose
Throttle cable No. 2
Guide
Pass the throttle cables
in front of the brake hose.
Throttle cable No. 1
Harness
Throttle cable No. 2
Handle switch
(LH)
VIEW B
Guide
Clutch hose
P
M
A
S
B
E
L
Throttle cable No. 1
Pass the throttle cable No. 1
upper the No. 2.
A
Throttle cable No. 2
Guide
0 mm
A
Harness
0 mm
Handle switch
(LH)
Clutch hose
SECT A – A
Clamp
SV1000K5/SK5
THROTTLE BODY INSTALLATION/HOSE ROUTING
Air cleaner side
Intake pipe side
Forward
Forward
15 – 25˚
Purge hose (E-33)
15 – 25˚
Breather
hose
15 – 25˚
Marking
(White)
Marking (Yellow)
Purge hose
(E-33 only)
Clamp
Pass the vacuum hose
upward of the PAIR hose.
Intake air pressure
sensor #1
PAIR air
vent hose
Don’t touch the high tension cord
and purge hose.
P
M
A
S
E
L
Wiring harness
Frame
Water guard
plate
0 – 20˚
Air cleaner
Intake air pressure
sensor #2
Pass the vacuum hose
upward of the fuel hose.
Air temperature sensor
18 N·m (1.8 kgf-m, 13 lb-ft)
Wiring harness
Intake pipe
(Rear)
Fuel
hose
Water temperature sensor
18 N·m (1.8 kgf-m, 13 lb-ft)
Marking
Intake pipe
(Front)
41
35˚
B
A
Be careful not to contact
the seat rail and reservoir
tank, when installing.
VIEW B
C
E
L
VIEW C
35˚
The white paint faces outside.
After the brake hose
union touching to
the stopper,
tighten the union bolt.
After positioning the clamp with the stopper,
tighten the clamp bolt.
P
M
A
S
Insert the hose until dead end.
VIEW A
After the brake hose union touching
to the stopper, tighten the union bolt.
Face the clamp ends backward.
The white paint faces outside.
Face the clamp ends backward.
42
SV1000K5/SK5
REAR BRAKE HOSE ROUTING (For SV1000K5)
28˚
B
A
Be careful not to contact
the seat rail and reservoir
tank, when installing.
VIEW B
C
E
L
VIEW C
35˚
The white paint faces outside.
After the brake hose
union touching to
the stopper,
tighten the union bolt.
After positioning the clamp with the stopper,
tighten the clamp bolt.
P
M
A
S
Insert the hose until dead end.
VIEW A
After the brake hose union touching
to the stopper, tighten the union bolt.
Face the clamp ends backward.
The white paint faces outside.
Face the clamp ends backward.
SV1000K5/SK5
REAR BRAKE HOSE ROUTING (For SV1000SK5)
43
Prepared by
P
M
A
S
E
L
December, 2004
Part No. 99501-39560-01E
Printed in Japan
44
WIRING DIAGRAM
SV1000K5 (For E-02, 19)
OIL
PRESSURE
SWITCH
HANDLEBAR SWITCH (R)
FRONT BRAKE
SWITCH
OFF
ON
OFF
FUEL
PUMP
BB
B/W
B/W
ON
OFF
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2
#1
INJECTOR
GEAR
POSITION
SWITCH
FUSE BOX
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
10 A
10 A
10 A
15 A
10 A
15 A
PAIR
SORENOID
VALVE
SENSOR
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
B/Y
Y/G
B/R
B/R
G/Bl
G
B
B
B
O/R
P/W
B/W
R
P/W
B/Br
Dg
B/Br
O/W
Br
O/B
Br
Lbl
G
O/Y
O/Bl
Bl/B
Bl
TP
SENSOR
IAT
SPEEDOMETER
SENSOR
3
G
Bl
Y
Y
Y
2
G
B/W
1
6
G
B/W
5
B
B
4
B/R
B
B/W
Gr/W
Bl
R
B
Gr/W
Y/R
HORN
PASSING DIMMER
BUTTON TURN SIGNAL LIGHT
SWITCH
SWITCH
SWITCH
FAN MOTOR
FAN
SWITCH
MOTOR
CLUTCH
LEVER
POSITION
SWITCH
FREE
Gr/B
Y/R
PUSH
HI
LO
R/B
B/R
PUSH
L
PUSH
R
STP
SENSOR
R/B
B/R
Y/R
Gr/B
B/R
Gr/R
B/W
O/G
W/R
Gr
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (L)
HORN
IAP
IAP
SENSOR SENSOR
ECT
#2
#1
SENSOR
B
B/W
BRAKE LIGHT/TAILLIGHT
Br
B/W
W/B
B
B/W
O/Y
O
O/G
B/R
W/Bl
Y/Bl
Y
W
R/W
Bl
P
B/W
B/Bl
B/Br
B/Br
P/B
R
R
Y
B/Br
Bl
Y
B
B/Br
G/B
R
B/W
O/Bl
B/R
Bl
R/B
B/R
Y/R
Gr/B
B/W
Lg
Lbl
B
O/G
Y/W
W/Bl
Y/Bl
B/W
B/Y
B/W
Lg
Lbl
B
O/G
O
W
Y
B/Y
B/Y
POSITION LIGHT
Gr/W
Br
B
B/W
B/W
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
B/G
Y
B/R
R/B
Bl/R
Bl/Y
W/G
R
B/Bl
G/B
P/W
Bl/W
Bl/B
Bl/G
O/G
R/W
O/R
G/Bl
P
Br/W
Dg
P/B
B/Br
W/B
B/W
Y/R
Gr/R
G
Lg
B/W
A
S
FRONT TURN SIGNAL LIGHT (L)
B
B
REAR TURN SIGNAL LIGHT (R)
P
M
Y
B/W
W
B/Bl
Br
B
B/W
B/W
LICENSE LIGHT
Br
B/W
B
B
B
B
B
Lg
B/W
HEADLIGHT
B
B/W
Y/B
Br/B
Y/B
O/W
R/W
Y/R
G/Y
O/W
B/Br
W/G
W/B
O/W
W/Bl
B/O
B
B
Lbl
Lg
O/B
O/W
Y/G
O
Y/W
O/G
W/B
B/R
O
O/R
Br
R/B
O/G
B/Lg
E
L
FRONT TURN SIGNAL LIGHT (R)
Lg
B/W
W/Bl
B/W
B/W
Y/G
B/Y
Bl
W/R
B/Br
B/W
B
Gr/W
Gr/B
Br
ON
OFF
M
IGNITION IGNITION
COIL #1 COIL #2
ECM
REAR BRAKE
TO
SWITCH FUEL PUMP SENSOR
RELAY
R
Br/W
B/Br
ON
HO2
SENSOR
O
W/B
PUSH
ON
OFF
LOCK
P
W
R
B
RESISTOR
STARTER
SWITCH
O/G
W/B
IGNITION SWITCH
F
OFF
RUN
Y/R
B/W
B/Lg
R/B
O
OFF
ON
Y/R
B/W
B/Lg
R/B
HAZARD ENGINESTOP
SWITCH SWITCH
B
SPEEDOMETER
B
Lbl
Lg
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
N
W
Gr
B
W
R
L
R
O
O/Y
Br
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: FUEL LEVEL INDICATOR LIGHT
: OIL, TEMP., FI INDICATOR LIGHT
G/Y
Bl/B
B
O/G
R/W
B/Lg
B/W
O/R
P/W
Br/B
B/G
B/W
R/B
Lg
Y
R
L
B
N
F
O
1
REGULATOR/
GENERATOR RECTIFIER
FREE
PUSH
SIDE-STAND
SWITCH
1: MAIN 30 A
STARTER
RELAY
STARTER
MOTOR
BATTERY
SV1000K5 (For E-24, 33)
HANDLEBAR SWITCH (R)
OFF
ON
W/R
Gr/R
B/W
O/W
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
B/G
Y
B/R
R/B
Bl/R
Bl/Y
R
B/Bl
G/B
P/W
Bl/W
Bl/B
Bl/G
O/W
R/W
O/R
G/Bl
Dg
P/B
B/Br
B/W
Y/R
Gr/R
G
Y/B
Br/B
W/Bl
B/W
B/W
Y/G
B/Y
Bl
W/R
Y/B
O/W
R/W
Y/R
G/Y
O/W
W/Bl
B/O
B
B/W
B
Gr/W
Gr/B
Br
ON
OFF
M
IGNITION IGNITION
COIL #1 COIL #2
B
Lbl
Lg
O/B
O/W
Y/G
O
Y/W
O/G
W/B
B/R
O
O/R
Br
R/B
O/G
B/Lg
ECM
FUEL
REAR BRAKE
TO
PUMP
SWITCH
FUEL PUMP SENSOR
RELAY
P
Br/W
OFF
ON
R
Br/W
B/Br
PUSH
O
W/B
OFF
RUN
ON
OFF
LOCK
P
W
R
B
RESISTOR
OFF
ON
OIL
PRESSURE
SWITCH
O/G
W/B
IGNITION SWITCH
F
FRONT BRAKE
SWITCH
Y/R
B/W
B/Lg
R/B
B
SPEEDOMETER
O
STARTER
SWITCH
B
Lbl
Lg
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
N
HAZARD ENGINESTOP
SWITCH SWITCH
Y/R
B/W
B/Lg
R/B
R
L
R
O
O/Y
Br
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: FUEL LEVEL INDICATOR LIGHT
: OIL, TEMP., FI INDICATOR LIGHT
G/Y
Bl/B
B
O/G
R/W
B/Lg
B/W
O/R
P/W
Br/B
B/G
B/W
R/B
Lg
Y
LICENSE LIGHT
Lg
B/W
HEADLIGHT
B
B/W
FRONT TURN SIGNAL LIGHT (L)
B
B/W
PUSH
HORN
PASSING DIMMER
BUTTON TURN SIGNAL LIGHT
SWITCH
SWITCH
SWITCH
FREE
CLUTCH
LEVER
POSITION
SWITCH
FAN MOTOR
FAN
SWITCH
MOTOR
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2
#1
INJECTOR
GEAR
POSITION
SWITCH
SENSOR
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
10 A
10 A
10 A
15 A
10 A
15 A
PAIR
SORENOID
VALVE
B/W
B/W
B/Y
Y/G
B/R
B/R
B
B
B
B/R
B/R
B/W
B/W
1
TP
IAT SENSOR
SENSOR SPEEDOMETER
FUSE BOX
B
B
B
B/R
B/R
B/W
B/W
3
G/Bl
G
B
B
B
2
G
Bl
Y
Y
Y
1
G
B/W
6
B
B
5
B/R
B
B/W
Gr/W
R/B
B/R
Y/R
Gr/B
Bl
R
B
Gr/W
Y/R
PUSH
HI
LO
R/B
B/R
ON
OFF
L
PUSH
R
STP
SENSOR
4
G
B/W
O/R
P/W
B/W
R
P/W
B/Br
Dg
B/Br
O/W
Br
O/B
Br
Lbl
G
O/Y
O/Bl
Bl/B
Bl
O/Y
O
O/G
B/R
W/Bl
Y/Bl
Y
W
R/W
B/Bl
B/Br
B/Br
P/B
R
B/Br
G/B
R
R
Y
B/Br
Bl
Y
B
Gr/W
B/W
O/Bl
B/R
Bl
R/B
B/R
Y/R
Gr/B
B/W
Lg
Lbl
B
O/G
Y/W
W/Bl
Y/Bl
B/W
B/Y
B/R
Gr
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (L)
HORN
IAP
IAP
SENSOR SENSOR
#1
ECT
#2
SENSOR
B
B/W
BRAKE LIGHT/TAILLIGHT
Br
B/W
W/B
A
S
Gr/B
Y/R
B
B/W
B
B
REAR TURN SIGNAL LIGHT (R)
Lg
B/W
P
M
Y
B/W
W
B/Bl
Bl
P
B/W
Lg
B/W
Br
B/W
E
L
FRONT TURN SIGNAL LIGHT (R)
B/W
Lg
Lbl
B
O/G
O
W
Y
B/Y
B/Y
R
L
B
N
F
O
REGULATOR/
GENERATOR RECTIFIER
FREE
PUSH
SIDE-STAND
SWITCH
1: MAIN 30 A
STARTER
MOTOR
STARTER
RELAY
BATTERY
SV1000SK5 (For E-02, 19)
OIL
PRESSURE
SWITCH
HANDLEBAR SWITCH (R)
FRONT BRAKE
SWITCH
OFF
ON
OFF
FUEL
PUMP
POSITION LIGHT(R)
E
L
FRONT TURN SIGNAL LIGHT (L)
B
B/W
ON
OFF
PUSH
HI
LO
HORN
PASSING DIMMER
BUTTON TURN SIGNAL LIGHT
SWITCH
SWITCH
SWITCH
FAN MOTOR
FAN
SWITCH
MOTOR
CLUTCH
LEVER
POSITION
SWITCH
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2
#1
INJECTOR
GEAR
POSITION
SWITCH
TP
SENSOR
IAT
SPEEDOMETER
SENSOR
3
FUSE BOX
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
15 A
10 A
15 A
10 A
15 A
PAIR
SORENOID
VALVE
SENSOR
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
B
B
B
B/R
B/R
B/W
B/W
B/Y
Y/G
B/R
B/R
G/Bl
G
B
B
B
G
Bl
Y
Y
Y
2
G
B/W
1
6
B/R
B
B/W
5
B
B
Bl
R
B
FREE
R/B
B/R
PUSH
L
PUSH
R
STP
SENSOR
4
G
B/W
O/R
P/W
B/W
R
P/W
B/Br
Dg
B/Br
O/W
Br
B/R
W/Bl
Y/Bl
Y
W
R/W
Bl
P
B/W
R
Y
B/Br
Bl
Y
B
B/Bl
B/Br
B/W
O/Bl
B/R
Bl
R/B
B/R
Y/R
Gr/B
B/W
Lg
Lbl
B
O/G
Y/W
W/Bl
Y/Bl
B/W
B/Y
B/W
Lg
Lbl
B
O/G
O
W
Y
B/Y
B/Y
B/R
Gr
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (L)
HORN
IAP
IAP
SENSOR SENSOR
ECT
#2
#1
SENSOR
B
B/W
BRAKE LIGHT/TAILLIGHT
Br
B/W
W/B
A
S
POSITION LIGHT (L)
B/Br
P/B
R
Br
B/W
B/Br
G/B
R
Br
B/W
Gr/W
B
B/W
Gr/W
B
B/W
Lg
B/W
P
M
Gr/W
Y/R
Y
B/W
W
Lg
Y
B/W
W
B
Br
Gr/B
Y/R
HEADLIGHT (L)
Lg
Y
B/W
W
B
Br
R/B
B/R
Y/R
Gr/B
HEADLIGHT (R)
B
B
REAR TURN SIGNAL LIGHT (R)
B
B
B
B
B
FRONT TURN SIGNAL LIGHT (R)
Y
B/W
W
Br
B/W
O/B
Br
Lbl
Lg
B/W
G
O/Y
Lg
B/W
LICENSE LIGHT
O/Bl
Bl/B
Bl
Br
B/W
O/Y
O
O/G
Br
B/W
Gr/R
B/W
O/G
W/R
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
B/G
Y
B/R
R/B
Bl/R
Bl/Y
W/G
R
B/Bl
G/B
P/W
Bl/W
Bl/B
Bl/G
O/G
R/W
O/R
G/Bl
P
Br/W
Dg
P/B
B/Br
W/B
B/W
Y/R
Gr/R
G
Y/B
O/W
R/W
Y/R
G/Y
O/W
B/Br
W/G
W/B
O/W
W/Bl
B/O
B
B
Lbl
Lg
O/B
O/W
Y/G
O
Y/W
O/G
W/B
B/R
O
O/R
Br
R/B
O/G
B/Lg
G/Y
Bl/B
B
O/G
R/W
B/Lg
B/W
O/R
P/W
Br/B
B/G
B/W
R/B
Lg
Y
Y/B
Br/B
ON
OFF
M
IGNITION IGNITION
COIL #1 COIL #2
ECM
REAR BRAKE
TO
SWITCH FUEL PUMP SENSOR
RELAY
W/Bl
B/W
B/W
Y/G
B/Y
Bl
W/R
B/Br
B/W
B
Gr/W
Gr/B
Br
ON
HO2
SENSOR
R
Br/W
B/Br
PUSH
ON
OFF
LOCK
P
W
R
B
RESISTOR
STARTER
SWITCH
O
W/B
IGNITION SWITCH
F
OFF
RUN
O/G
W/B
O
OFF
ON
Y/R
B/W
B/Lg
R/B
B
SPEEDOMETER
Y/R
B/W
B/Lg
R/B
N
HAZARD ENGINESTOP
SWITCH SWITCH
W
Gr
B
W
R
L
B
Lbl
Lg
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: FUEL LEVEL INDICATOR LIGHT
: OIL, TEMP., FI INDICATOR LIGHT
R
O
O/Y
Br
R
L
B
N
F
O
1
REGULATOR/
GENERATOR RECTIFIER
FREE
PUSH
SIDE-STAND
SWITCH
1: MAIN 30 A
STARTER
RELAY
STARTER
MOTOR
BATTERY
SV1000SK5 (For E-03, 24, 28, 33)
HANDLEBAR SWITCH (R)
OFF
ON
POSITION LIGHT(R)
E
L
FRONT TURN SIGNAL LIGHT (L)
B
B/W
PUSH
HORN
PASSING DIMMER
BUTTON TURN SIGNAL LIGHT
SWITCH
SWITCH
SWITCH
FREE
CLUTCH
LEVER
POSITION
SWITCH
FAN MOTOR
FAN
SWITCH
MOTOR
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2
#1
INJECTOR
GEAR
POSITION
SWITCH
SENSOR
1. HEAD HI
2. HEAD LO
3. FUEL
4. IGNITION
5. SIGNAL
6. FAN
15 A
15 A
10 A
15 A
10 A
15 A
PAIR
SORENOID
VALVE
B/W
B/W
B/Y
Y/G
B/R
B/R
B
B
B
B/R
B/R
B/W
B/W
1
TP
IAT SENSOR
SENSOR SPEEDOMETER
FUSE BOX
B
B
B
B/R
B/R
B/W
B/W
3
G/Bl
G
B
B
B
2
G
Bl
Y
Y
Y
1
G
B/W
6
B/R
B
B/W
5
B
B
Bl
R
B
R/B
B/R
PUSH
HI
LO
4
G
B/W
O/R
P/W
B/W
R
P/W
B/Br
Dg
B/Br
O/W
Br
B/R
W/Bl
Y/Bl
Y
W
R/W
Bl
P
B/W
R
Y
B/Br
Bl
Y
B
B/Bl
B/Br
B/W
O/Bl
B/R
Bl
R/B
B/R
Y/R
Gr/B
B/W
Lg
Lbl
B
O/G
Y/W
W/Bl
Y/Bl
B/W
B/Y
B/W
Lg
Lbl
B
O/G
O
W
Y
B/Y
B/Y
ON
OFF
L
PUSH
R
STP
SENSOR
IAP
IAP
SENSOR SENSOR
#1
ECT
#2
SENSOR
W/R
Gr/R
B/W
Gr
B/W
W/B
B
B/W
REAR TURN SIGNAL LIGHT (L)
HORN
B/R
B
B/W
BRAKE LIGHT/TAILLIGHT
Br
B/W
W/B
A
S
POSITION LIGHT (L)
B/Br
P/B
R
Br
B/W
B/Br
G/B
R
Br
B/W
Gr/W
B
B/W
Gr/W
B
B/W
B
B
REAR TURN SIGNAL LIGHT (R)
Lg
B/W
P
M
Lg
Y
B/W
W
B
Br
Gr/W
Y/R
Y
B/W
W
Lg
Y
B/W
W
B
Br
Gr/B
Y/R
HEADLIGHT (R)
HEADLIGHT (L)
R/B
B/R
Y/R
Gr/B
Y
B/W
W
Br
B/W
O/B
Br
Lbl
Lg
B/W
FRONT TURN SIGNAL LIGHT (R)
G
O/Y
Lg
B/W
LICENSE LIGHT
O/Bl
Bl/B
Bl
Br
B/W
O/Y
O
O/G
Br
B/W
O/W
B/Br
Bl/W
Bl/B
Bl/G
Bl/R
Bl/Y
R
B/G
Y
B/R
R/B
Bl/R
Bl/Y
R
B/Bl
G/B
P/W
Bl/W
Bl/B
Bl/G
O/W
R/W
O/R
G/Bl
Dg
P/B
B/Br
B/W
Y/R
Gr/R
G
Y/B
Br/B
Y/B
O/W
R/W
Y/R
G/Y
O/W
W/Bl
B/O
B
B/W
B
Gr/W
Gr/B
Br
ON
OFF
M
IGNITION IGNITION
COIL #1 COIL #2
B
Lbl
Lg
O/B
O/W
Y/G
O
Y/W
O/G
W/B
B/R
O
O/R
Br
R/B
O/G
B/Lg
G/Y
Bl/B
B
O/G
R/W
B/Lg
B/W
O/R
P/W
Br/B
B/G
B/W
R/B
Lg
Y
ECM
FUEL
REAR BRAKE
TO
PUMP
SWITCH
FUEL PUMP SENSOR
RELAY
P
Br/W
OFF
ON
W/Bl
B/W
B/W
Y/G
B/Y
Bl
W/R
PUSH
R
Br/W
B/Br
OFF
RUN
ON
OFF
LOCK
P
W
R
B
RESISTOR
OFF
ON
O
W/B
IGNITION SWITCH
F
OIL
PRESSURE
SWITCH
FRONT BRAKE
SWITCH
O/G
W/B
B
SPEEDOMETER
O
STARTER
SWITCH
Y/R
B/W
B/Lg
R/B
N
HAZARD ENGINESTOP
SWITCH SWITCH
Y/R
B/W
B/Lg
R/B
R
L
B
Lbl
Lg
O/B
O/W
Y/G
O/R
Y/W
B/R
B/Bl
: TURN SIGNAL INDICATOR LIGHT (R)
: TURN SIGNAL INDICATOR LIGHT (L)
: HI-BEAM INDICATOR LIGHT
: NEUTRAL INDICATOR LIGHT
: FUEL LEVEL INDICATOR LIGHT
: OIL, TEMP., FI INDICATOR LIGHT
R
O
O/Y
Br
R
L
B
N
F
O
REGULATOR/
GENERATOR RECTIFIER
FREE
PUSH
SIDE-STAND
SWITCH
1: MAIN 30 A
STARTER
MOTOR
STARTER
RELAY
BATTERY
Printed in Japan
K5