Suzuki DL1000AL4 Owner's manual

Brand: Suzuki

Model: DL1000AL4

Type: Owner's manual

December ’13 (TK) 21

99505-01134-01E

FOREWORD

This motorcycle has been designed and produced utilizing Suzuki’s most modern

technology. The finest product, however, cannot perform properly unless it is cor-

rectly assembled and serviced. This set-up manual has been produced to aid you in

properly assembling and servicing this motorcycle.

Please read this manual and follow its instructions carefully. To emphasize special

information, the symbol

 and the words WARNING, CAUTION, NOTICE and

NOTE have special meanings. Pay particular attention to messages highlighted by

these signal words:



Indicates a potential hazard that could result in death or serious injury.



Indicates a potential hazard that could result in minor or moderate injury.

Indicates a potential hazard that could result in motorcycle or equipment

damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

This set-up manual is based on a motorcycle of standard specification. Some minor

differences from this manual may be found in other specifications.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

 CAUTION

Assembling the vehicle in poor working condi-

tion can be hazardous.

Place the packed vehicle on a level floor where

it is clean and spacious.

 CAUTION

Assembling the vehicle without proper clothes

and protective gear can be hazardous. You can

be injured if you do not wear proper clothes

and protective gear.

Be sure to wear proper clothes and shoes for

assembling and wear protective glasses, mask

or gloves as necessary.

UNCRATING THE MOTORCYCLE

Cut the strap by using scissors.

A: Strap

Remove the carton.

A: Crate

 CAUTION

Metal crates may have sharp edges and may

cause injury.

Wear proper protective clothes and gear.

Remove the strap.

Take out the front wheel assembly from the crate base.

A: Strap

B: Front wheel assembly

Remove the strap.

Take out the various component parts packaged from

the crate base.

A: Strap

B: Component parts

Remove the bolts of the bracket.

A: Bolt

Remove the bolts from the crate.

A: Bolt

Lift the steel frame to separate it from the base of the

crate.

Carefully remove the various component parts pack-

aged around the motorcycle.

A: Steel frame

B: Crate base

 CAUTION

Careless steel frame separation can injure a

person.

Lift the steel frame with two persons.

Wear proper protective clothes and gear.

NOTE:

Be careful not to damage the motorcycle when

separating the steel frame.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

Windscreen 1

Stepped Allen screw 4 6 × 20 mm

Rubber cushion 4 OD:18.0 T:10.0

Rubber cap 4

Handlebars assembly 1

Clamp 2

Flange bolt 4 8 × 30 mm

Burring washer 4 OD:13.0 ID:8.5

Screw 1

5 × 45 mm

For right switch

Screw 2

5 × 25 mm

For left switch

Strap 2 L:140

Holder 2 For master cylinder

Flange bolt 4 6 × 22 mm

Handlebar balancer

weight

2 Right and Left

Screw 2 6 × 105 mm

Flange rubber cushion 2 L:34.0

Spacer 2 L:50.0

Washer 2

OD:16.0 ID:6.5

T:1.6

Rubber cushion 2 L:15.0

Spacer nut 2 6 mm

E Rear view mirror 2 Right and Left

Item Part Name Q’ty Remarks

Front fender 1

Stepped Allen screw 6 6 × 16 mm

Clip 1

For front brake

hose

Front fender 1

Stepped Allen screw 4 6 × 16 mm

Reflex reflector assembly 2 Right and Left

Clip 1

For front brake

hose

G Front wheel assembly 1

Front axle nut 1 24 mm

Front wheel spacer 1 Right

I Flange bolt 2

6 × 12 mm

For ABS sensor

assembly

J Case lock assembly 3

For side and rear

case

(Optional parts)

K Washer 2 OD:13.0 ID:6.5

Battery electrolyte

container

M Owner’s manual set 1

N Warning label set 7

For

E-21 CC selection

O Warning label set 4

For

E-21 CD selection

NOTE:

• The parts shown as Item J in the above table are on the tray under the seat.

• The parts shown as Item F2, N and O in the above table are supplied for limited specifications.

• Use washers of Item K for mounting the license plate.

• Please hand over the parts shown as Item J and M in the above table to your customer together with motor-

cycle.

G F1,F2 A B E C D

DC E

The photograph shown indicates the parts dismounted

from the motorcycle in addition to the items shown in

the preceding page.

A: Front brake master cylinder

B: Throttle assembly

C: Clutch master cylinder

D: Left switch

E: Right switch

F: Front wheel ABS sensor assembly

G: Case lock assembly

Before assembling the motorcycle, thoroughly

understand the “Safety Check Out” described on

page 52.

After completion of assembly, carefully check the

motorcycle referring to the “Safety Check Out”,

then deliver the motorcycle to the customer.

ASSEMBLY

LEFT RIGHT

REMOVING THE BRACKET

Remove the bolts to take off the front brake and clutch

master cylinder from the bracket.

A: Front brake master cylinder

B: Clutch master cylinder

C: Bolt

D: Bracket

Remove the bolts to take off the bracket from the han-

dlebar holder.

A: Bracket

B: Bolt

NOTE:

• Keep the position of front brake and clutch mas-

ter cylinder with its cap facing upwards until it is

installed.

• The bolts are not necessary to assemble the

motorcycle.

NOTE:

• Be careful not to damage the fuel tank.

• The bracket and bolts are not necessary to

assemble the motorcycle.

HANDLEBARS

Loosen the right switch retaining screws and throttle

housing retaining bolts.

Insert the right switch and throttle assembly onto the

handlebars.

A: Throttle assembly

B: Right switch

C: Handlebars

Install the handlebars assembly with the two clamps,

four bolts and washers.

A: Clamp

B: 8 × 30 mm flange bolt

C: Burring washer OD:13.0 mm ID:8.5 mm

D: Punch mark

E: Dot mark

Tighten the handlebar clamp bolts to the specified

torque.

 Handlebar clamp bolt: 23 N·m (2.3 kgf-m)

A: 8 × 30 mm flange bolt

B: 8 × 30 mm flange bolt

NOTE:

• Install the burring washer in the direction as

shown in the illustration.

• Install each clamp with the punch mark facing

front.

• Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

NOTE:

• First tighten the bolt A of the front side with

specified torque and then tighten the bolt B of

the rear side.

• Make sure that the clamp has no clearance at the

front side.

FRONT

A: Front brake hose

B: Throttle cables

C: Right switch wiring harness

D: Clutch hose

E: Left switch wiring harness

THROTTLE

Install the throttle assembly with two Allen bolts.

A: Throttle assembly

B: Allen bolt

C: Dot mark

RIGHT SWITCH

Insert the boss of right switch housing into the hole on

the handlebars.

Install the right switch assembly with the two screws.

A: Boss

B: Hole

C: 5 × 45 mm screw

NOTE:

• The line drawings on page 47, 48, 49, 50 and 51

show the proper routing of the control cables,

hose and wirings.

• Refer to them in addition to following the instruc-

tions carefully.

NOTE:

Align the dot mark on the handlebars with the mat-

ing surface of the throttle housing.

 WARNING

Improper throttle installing can interfere with

smooth throttle grip operation. It can result in

an accident.

Check to ensure that the throttle operates

freely and closes automatically.

NOTICE

Pinching the lead wires in the parts can short or

break circuit.

Check the lead wire routing when assembling

the switch.

FRONT BRAKE MASTER CYLINDER

Install the front brake master cylinder onto the handle-

bars.

A: Holder

B: Front brake master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

Tighten the front brake master cylinder mounting bolts

to the specified torque.

 Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: 6 × 22 mm flange bolt

B: 6 × 22 mm flange bolt

C: Holder

D: Front brake master cylinder

E: Handlebars

Connect the lead wire coupler to the front brake light

switch.

A: Front brake light switch

B: Lead wire coupler

NOTE:

• Install the holder in position according to the

mark “UP”.

• Align the dot mark on the handlebars with the

master cylinder-to-holder fitting surface.

NOTE:

• First tighten the bolt A of the upper side with

specified torque and then tighten the bolt B of

the lower side.

• Make sure that the holder has no clearance at

the upper side.

LEFT SWITCH

Insert the boss of left switch housing into the hole on

the handlebars.

Install the left switch assembly with two screws.

A: Boss

B: Hole

C: 5 × 25 mm screw

CLUTCH MASTER CYLINDER

Install the clutch master cylinder onto the handlebars.

A: Holder

B: Clutch master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

Tighten the clutch master cylinder mounting bolts to

the specified torque.

 Clutch master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: 6 × 22 mm flange bolt

B: 6 × 22 mm flange bolt

C: Holder

D: Clutch master cylinder

E: Handlebars

NOTICE

Pinching the lead wires in the parts can short or

break circuit.

Check the lead wire routing when assembling

the switch.

NOTE:

• Install the holder in position according to the

mark “UP”.

• Align the dot mark on the handlebars with the

master cylinder-to-holder fitting surface.

NOTE:

• First tighten the bolt A of the upper side with

specified torque and then tighten the bolt B of

the lower side.

• Make sure that the holder has no clearance at

the upper side.

Connect the lead wires to the clutch lever position

switch.

A: Clutch lever position switch

B: Lead wire

RIGHT

CLAMP

Clamp the right switch wiring harness and front brake

hose union with strap.

A: Strap L:140 mm

B: Front brake hose union

C: Right switch wiring harness

LEFT

Clamp the left switch wiring harness and clutch hose

union with strap.

A: Strap L:140 mm

B: Clutch hose union

C: Left switch wiring harness

NOTE:

Cut off the excess strap as shown in the photo-

graph.

OUTSIDE

NOTE:

Cut off the excess strap as shown in the photo-

graph.

OUTSIDE

HANDLEBAR BALANCER

Assemble the handlebar balancer parts as shown.

A: Balancer weight

B: 6 × 105 mm screw

C: Flange rubber cushion L:34.0 mm

D: Spacer L:50.0 mm

E: Washer OD:16.0 mm ID:6.5 mm T:1.6 mm

F: Rubber cushion L:15.0 mm

G: 6 mm spacer nut

Tighten the screw a little.

Insert the balancer sub-assembly into the handlebar

end all the way.

Tighten the screw securely.

A: Balancer assembly

 WARNING

Improper handlebar balancer fitting can inter-

fere with smooth throttle grip operation. It can

result in an accident.

Check to ensure that the throttle operates

freely and closes automatically.

TAKING OUT THE MOTORCYCLE

Bind a hoist band around the handlebar clamps as

shown in the photograph.

A: Hoist band

Remove the crate axle bracket from the crate base.

A: Crate axle bracket

B: Bolt

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Pull the crate base forward, then balance the

motorcycle.

NOTE:

Lift the motorcycle a little by using a hoist to pre-

vent the motorcycle from falling down.

NOTICE

Binding a hoist band to the handlebar or grips

can damage the motorcycle parts.

Be sure to bind a hoist band around the handle-

bar clamps.

NOTE:

The bracket and bolt are not necessary to assem-

ble the motorcycle.

FRONT FENDER

Install the front fender to the front fork legs.

A: Front fender

B: 6 × 16 mm stepped Allen screw

C: Front fork leg

(FOR LIMITED SPECIFICATIONS)

Install the front fender to the front fork legs.

A: Front fender

B: 6 × 16 mm stepped Allen screw

C: Front fork leg

D: Reflex reflector assembly

E: Reflex reflector stay

FRONT BRAKE HOSE

Install the brake hose to the brake hose guide with the

protector properly in place.

A: Hose guide

B: Brake hose

C: Protector

Fit the clip to the protector of brake hose.

Install the clip to the hole of front fender.

A: Clip

B: Brake hose

C: Protector

D: Hole

E: Front fender

NOTE:

When installing the reflex reflector assembly,

tighten the reflex reflector stay.

FRONT REAR

BRAKE DISC

To prevent brake squeaking and pad contamination,

carefully clean the front and rear brake disc plates with

alcohol or other non-petroleum based solvent.

This will remove the rust-preventive coating and dirt.

FRONT WHEEL

When installing the front wheel onto the axle, special

attention must be paid to the arrow of the rotational

direction on the tire sidewall.

When the tire is properly installed, the arrow must indi-

cate forward rotation of the wheel.

NOTE:

The ABS sensor side is right side.

 WARNING

Installing the front wheel in the reverse direc-

tion can be hazardous. The tire for this motor-

cycle is directional. Therefore, the motorcycle

may have unusual handling if the wheel is

installed incorrectly.

Install the front wheel in the specified direction,

as indicated by the arrow on the sidewall of the

tire.

FRONT

Loosen the axle clamp bolts.

Remove the front axle from the fork legs.

A: Axle clamp bolt

B: Front axle

Mount the front wheel assembly properly.

A: Right fork leg

B: Left fork leg

C: Front wheel spacer (Right)

D: Front axle

E: Axle nut (24 mm flange nut)

Temporarily remove the right front brake caliper.

A: Brake caliper

B: Caliper mounting bolt

C: Pad

D: Supporter

NOTE:

• Put a suitable pad C to prevent the motorcycle

from being damaged.

• Do not remove the supporter inserted between

the brake pads until the brake caliper is installed.

LEFT

Remove the supporter from the brake pad of the left

front brake caliper.

A: Supporter

RIGHT LEFT

Attach the front wheel spacer to the front wheel hub.

Carefully insert the front brake disc plate between the

caliper brake pads.

A: Front wheel spacer

B: Oil seal (Lip)

C: Pads

D: Disc plate

Insert the front axle from the left side of fork leg and fix

the front wheel assembly to the front fork.

A: Front axle

B: Oil seal (Lip)

NOTE:

• When attaching the front wheel spacer, be care-

ful not to damage the oil seal lip.

• The flange side of the spacer faces the right fork

leg.

NOTICE

Forcing to install the front axle can damage the

motorcycle.

Align the shaft line of front forks and wheel.

Install the front axle by hand.

NOTE:

When installing the front axle, be careful not to

damage the oil seal lip.

Tighten the front axle nut to the specified torque while

holding the front axle.

 Front axle nut: 100 N·m (10.0 kgf-m)

A: Axle nut

FRONT BRAKE CALIPER

Remove the supporter from the brake pad of the right

front brake caliper.

A: Supporter

B: Brake caliper (Right)

Set the front brake caliper so the brake disc plate is

inserted between two brake pads.

Install the front brake caliper.

A: Pads

B: Disc plate

C: Brake caliper (Right)

D: Caliper mounting bolt

RIGHT LEFT

Tighten the front brake caliper mounting bolts to the

specified torque.

 Front brake caliper mounting bolt:

39 N·m (3.9 kgf-m)

A: Brake caliper

B: Caliper mounting bolt

NOTE:

Make sure that both the right and left caliper

mounting bolts are tightened with specified torque.

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Suzuki DL1000AL4 Owner's manual

Suzuki DL1000AL4 Owner's manual

Suzuki DL1000AL4 Owner's manual

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