Suzuki DL1000 V-Storm 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: DL1000 V-Strom Year: 2002 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Segment: Adventure Touring Motorcycle Key Characteristics: Versatile, comfortable for...

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标签: 2002 DL1000 V-Storm Motorcycle Motorcycles Suzuki V Storm Models

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DL1000 V-Strom

Year:

Product Type:

Factory Service Repair Manual

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Key Characteristics:

Versatile, comfortable for long distances, capable on varied terrain

Competitive Analysis

Primary Competitors:

BMW R1150GS, Honda VFR800/Interceptor (in some aspects), Kawasaki KLR650 (though lower displacement)

Key Features

Engine Architecture:

V-twin engine, known for torque and character

Design Philosophy:

Combining sportbike performance with touring comfort and light off-road capability

Value Proposition

Manual Benefit:

Empowers owners and technicians to perform accurate diagnostics and repairs, maximizing the lifespan and performance of the motorcycle.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and adjustment procedures for the Suzuki DL1000 V-Strom 2002

Target Audience:

Mechanics and DIY enthusiasts

Page Count

Estimated Pages:

Over 300 (typical for this era and model complexity)

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Likely printed or PDF (digital reprint)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of engine components (pistons, cylinders, crankshaft, camshafts, valves, etc.)

Fuel System:

Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, lines, and filters

Ignition System:

Ignition coils, spark plugs, ECU control, sensor diagnostics

Cooling System:

Radiator, coolant passages, water pump, thermostat, fan control

Exhaust System:

Exhaust pipes, catalytic converter, mufflers, lambda sensors (if applicable)

Transmission:

Clutch operation, gear shifting mechanism, internal gearbox components, lubrication

Drivetrain:

Final drive (chain and sprockets), swingarm, bearings

Brakes:

Front and rear brake systems (calipers, discs, master cylinders, fluid lines), ABS system (if equipped)

Suspension:

Front telescopic forks (damping, spring preload adjustment), rear shock absorber (preload, rebound adjustment), linkages

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter motor, instrumentation, ECU

Frame And Bodywork:

Chassis components, fairings, seat, fuel tank, handlebars, rider controls, luggage systems (mounting)

Wheels And Tires:

Wheel removal and installation, tire replacement, balancing, bearing maintenance

Procedures Included

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, chain adjustment, lubrication points

Troubleshooting:

Diagnostic procedures for common issues, fault codes, symptom-based troubleshooting

Repair:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation

Adjustment:

Carburetor (if applicable, though DL1000 is fuel injected), idle speed, clutch lever, brake levers, suspension settings

Calibration:

Throttle position sensor calibration, idle air control adjustment (if applicable)

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to in-depth engine and electrical diagnostics and rebuilds

Diagnostic Tools:

Mentions diagnostic connectors and procedures, potentially requiring Suzuki diagnostic tools for advanced fault finding

Torque Specifications:

Detailed torque values for all fasteners and critical components

Clearances:

Specifications for valve clearances, bearing clearances, and other critical component clearances

Electrical Diagnostics:

Includes detailed wiring diagrams and troubleshooting trees for electrical issues

📊 Manual Specifications

File Format

Digital Format:

PDF (if digital, searchable text, high resolution for diagrams)

Print Quality

Print Quality:

High-quality reproductions of original factory diagrams and text

Binding Type

Binding Type:

Perfect bound or spiral bound (for ease of use and flat opening)

Paper Type

Paper Type:

Durable, coated paper stock to resist grease and moisture in a workshop environment

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, V-twin, DOHC, 8-valve

Displacement:

996 cc

Bore X Stroke:

98.0 mm x 66.0 mm

Compression Ratio:

11.3:1

Performance

Horsepower:

Approx. 98 HP @ 8,800 RPM (crank)

Torque:

Approx. 76 lb-ft @ 6,400 RPM (crank)

Fuel System

Fuel Delivery:

Digital Fuel Injection with dual 42mm throttle bodies

Fuel Type:

Unleaded gasoline, 91 octane or higher recommended

Lubrication

Oil Capacity With Filter Change:

Approx. 3.2 L (3.4 US qt)

Oil Type Specification:

API SG or SH, JASO MA (e.g., Suzuki Extreme SS 10W-40)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Sealed O-ring chain

Gear Ratios:

Specific ratios detailed in manual, crucial for engine tuning and performance analysis.

📐 Dimensions

Exterior

Length:

Approx. 2260 mm (89.0 in)

Width:

Approx. 840 mm (33.1 in)

Height:

Approx. 1445 mm (56.9 in)

Wheelbase:

Approx. 1535 mm (60.4 in)

Weights

Dry Weight:

Approx. 207 kg (456 lbs)

Wet Weight:

Approx. 231 kg (510 lbs)

Capacities

Fuel Tank Capacity:

22 L (5.8 US gal)

🛡️ Safety Features

Ratings

Optional ABS (Anti-lock Braking System) available on some models/markets. Manual will detail ABS system components and diagnostics if equipped.

Active Features

Braking System:

Dual front discs with 4-piston calipers, single rear disc with 2-piston caliper.

Passive Features

Lighting:

Dual headlights, LED taillight, turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, LCD display for odometer, trip meters, fuel gauge, clock, and warning lights. Manual details diagnostic indicators.

Driver Assistance

Optional ABS system, detailed troubleshooting in manual.

Connectivity

Diagnostic Port:

Key diagnostic connector for ECU communication and fault code retrieval.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Valve Clearance Check:

Every 24,000 km (15,000 miles) or 24 months.

Air Filter Cleaning/Replacement:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Fluid Specifications

Coolant:

Suzuki Super Long Life Coolant or equivalent (50/50 mix with distilled water)

Brake Fluid:

DOT 4

Clutch Fluid:

DOT 4 (hydraulic clutch)

Known Issues

Stator Reliability:

Early models were known for stator failures. Manual will provide testing procedures.

Fuel Pump Strainer:

Clogging of fuel pump strainer can lead to fuel delivery issues. Manual will detail access and cleaning.

Throttle Control Body Cleaning:

Carbon buildup can affect idle and throttle response. Manual will cover cleaning procedures.

Parts Number Reference

Oil Filter Part Number:

Likely 16510-07J00-000 or equivalent.

Spark Plug Part Number:

NGK CR9E or similar.

📚 Vehicle History

Brand Heritage

Heritage:

Suzuki has a long history in motorcycle manufacturing, known for reliable and performance-oriented engines, particularly their V-twins.

Model Evolution

V Strom Lineage:

The DL1000 V-Strom was Suzuki's entry into the large-displacement adventure touring segment, leveraging the TL1000 engine platform.

First Generation:

This 2002 model represents the first generation of the DL1000 V-Strom.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 2002 model may vary, the V-Strom line is generally recognized for its practicality and value in the adventure touring segment.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its touring capability and V-twin character, though some mechanical quirks were noted and addressed in later revisions.