SV1000/S

USE THIS MANUAL WITH:

SV1000S/SV1000 SERVICE MANUAL (99500-39251-01E)

99501-39560-01E
 SV1000K5/SK5 1

SV1000K5/SK5

FOREWORD
This manual describes service data, service specifications and servicing procedures which dif-
fer 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

L E
COUNTRY AND AREA CODES.......................................................................... 2

P
SPECIFICATIONS (SV1000K5) .......................................................................... 3
SPECIFICATIONS (SV1000SK5) ........................................................................ 5

M
SERVICE DATA (SV1000K5).............................................................................. 7
SERVICE DATA (SV1000SK5) ...........................................................................16

A
CRANKCASE-CRANKSHAFT BEARING SELECTION .....................................25

S
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

© COPYRIGHT SUZUKI MOTOR CORPORATION 2004

2 SV1000K5/SK5

COUNTRY AND AREA CODES

The following codes stand for the applicable country (-ies) and area (-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

SV1000K5 : JS1BX431200100001 –
E-02 U.K.
SV1000SK5 : JS1BX412200100001 –
E-03 U.S.A. (Except for California)
SV1000K5/SV1000SK5
E-28 Canada
: JS1VT54A 52100001 –
E-33 California (U.S.A.)
SV1000K5 : JS1BX431100100001 –
SV1000U2K5 : JS1BX521100100001 –
E-19 E.U.
SV1000SK5 : JS1BX412100100001 –
SV1000S2K5 : JS1BX612100100001 –
SV1000K5 : JS1BX441300100001 –
E-24 Australia
SV1000SK5 : JS1BX442300100001 –

L E
M P
S A
 SV1000K5/SK5 3

SPECIFICATIONS (SV1000K5)
DIMENSIONS AND DRY MASS
Overall length ..................................................................................... 2 080 mm (81.9 in)
Overall width....................................................................................... 785 mm (30.9 in)
Overall height ..................................................................................... 1 080 mm (42.5 in)
Wheelbase ......................................................................................... 1 445 mm (56.9 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 .................................................................................................... 4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
Number of cylinders ........................................................................... 2
Bore.................................................................................................... 98.0 mm (3.858 in)
Stroke ................................................................................................. 66.0 mm (2.598 in)
Displacement...................................................................................... 996 cm3 (60.8 cu. in)
Compression ratio .............................................................................. * 11.6 : 1
Fuel system ........................................................................................ Fuel injection
Air cleaner .......................................................................................... Non-woven fabric element
Starter system .................................................................................... Electric
Lubrication system ............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min

DRIVE TRAIN
Clutch ................................................................................................. Wet multi-plate type
Transmission....................................................................................... 6-speed constant mesh

E
Gearshift pattern ................................................................................ 1-down, 5-up
Primary reduction ratio ....................................................................... 1.838 (57/31)
Gear ratios, Low ............................................................................... 2.666 (32/12)

L
2nd................................................................................ 1.933 (29/15)
3rd ................................................................................ 1.500 (27/18)

P
4th................................................................................. 1.227 (27/22)
5th................................................................................. 1.086 (25/23)
Top ................................................................................ 1.000 (24/24)
Final reduction ratio ............................................................................ 2.352 (40/17)

M
Drive chain.......................................................................................... RK50SMOZ1, 110 links

A
CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................ Link type, coil spring, oil damped

S
Front suspension stroke ..................................................................... 120 mm (4.7 in)
Rear wheel travel................................................................................ 130 mm (5.1 in)
Caster................................................................................................. 24.8°
Trail ..................................................................................................... 107 mm (4.2 in)
Steering angle .................................................................................... 32° (right & left)
Turning radius ..................................................................................... 3.0 m (9.84 ft)
Front brake ......................................................................................... Disc brake, twin
Rear brake.......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17M/C (58W), tubeless
Rear tire size ...................................................................................... 180/55ZR17M/C (73W), tubeless

ELECTRICAL
Ignition type ........................................................................................ Electronic ignition (Transistorized)
Ignition timing ..................................................................................... 5° B.T.D.C. at 1 200 r/min
Spark plug .......................................................................................... NGK CR8EK or DENSO U24ETR
Battery ................................................................................................ 12 V 43.2 kC (12 Ah)/10 HR
Generator ........................................................................................... Three-phase A.C. generator
Main fuse ............................................................................................ 30 A
Fuse ................................................................................................... 10/10/10/15/10/15 A
Headlight ............................................................................................ 12 V 60/55 W
Position light ....................................................................................... 12 V 5 W ................................................ E-02, 19
License plate light............................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Brake light/Tail light............................................................................. LED
Speedometer light .............................................................................. LED
Tachometer light ................................................................................. LED
Fuel level indicator light ...................................................................... LED
Turn signal indicator light.................................................................... LED
Neutral indicator light.......................................................................... LED
High beam indicator light .................................................................... LED
Oil pressure/Coolant temperature/Fuel injection warning light ........... LED
4 SV1000K5/SK5

CAPACITIES
Fuel tank ............................................................................................. 16 L (4.2/3.5 US/Imp gal)................... E-33
17 L (4.5/3.7 US/Imp gal)................... Others
Engine oil, oil change......................................................................... 2 700 ml (2.9/2.4 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 300 ml (3.5/2.9 US/Imp qt)
Coolant................................................................................................ 2.2 L (2.3/1.9 US/Imp qt)

These specifications are subject to change without notice.

L E
M P
S A
 SV1000K5/SK5 5

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 .................................................................................................... 4-stroke, Liquid-cooled, DOHC, 90° degree V-twin
Number of cylinders ........................................................................... 2
Bore.................................................................................................... 98.0 mm (3.858 in)
Stroke ................................................................................................. 66.0 mm (2.598 in)
Displacement...................................................................................... 996 cm3 (60.8 cu. in)
Compression ratio .............................................................................. * 11.6 : 1
Fuel system ........................................................................................ Fuel injection
Air cleaner .......................................................................................... Non-woven fabric element
Starter system .................................................................................... Electric
Lubrication system ............................................................................. Wet sump
Idle speed ........................................................................................... 1 200 ± 100 r/min

DRIVE TRAIN
Clutch ................................................................................................. Wet multi-plate type
Transmission....................................................................................... 6-speed constant mesh

E
Gearshift pattern ................................................................................ 1-down, 5-up
Primary reduction ratio ....................................................................... 1.838 (57/31)
Gear ratios, Low ............................................................................... 2.666 (32/12)

L
2nd................................................................................ 1.933 (29/15)
3rd ................................................................................ 1.500 (27/18)

P
4th................................................................................. 1.227 (27/22)
5th................................................................................. 1.086 (25/23)
Top ................................................................................ 1.000 (24/24)
Final reduction ratio ............................................................................ 2.352 (40/17)

M
Drive chain.......................................................................................... RK50SMOZ1, 108 links

A
CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................ Link type, coil spring, oil damped

S
Front suspension stroke ..................................................................... 115 mm (4.5 in)
Rear wheel travel................................................................................ 130 mm (5.1 in)
Caster................................................................................................. 24.5°
Trail ..................................................................................................... 98 mm (3.9 in)
Steering angle .................................................................................... 30° (right & left)
Turning radius ..................................................................................... 3.2 m (10.50 ft)
Front brake ......................................................................................... Disc brake, twin
Rear brake.......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17M/C (58W), tubeless
Rear tire size ...................................................................................... 180/55ZR17M/C (73W), tubeless

ELECTRICAL
Ignition type ........................................................................................ Electronic ignition (Transistorized)
Ignition timing ..................................................................................... 5° B.T.D.C. at 1 200 r/min
Spark plug .......................................................................................... NGK CR8EK or DENSO U24ETR
Battery ................................................................................................ 12 V 43.2 kC (12 Ah)/10 HR
Generator ........................................................................................... Three-phase A.C. generator
Main fuse ............................................................................................ 30 A
Fuse ................................................................................................... 15/15/10/15/15/10 A
Headlight ............................................................................................ 12 V 60/55 W × 2 (H4)
Position light ....................................................................................... 12 V 5 W × 2
License plate light............................................................................... 12 V 5 W
Turn signal light .................................................................................. 12 V 21 W
Brake light/Tail light............................................................................. LED
Speedometer light .............................................................................. LED
Tachometer light ................................................................................. LED
Fuel level indicator light ...................................................................... LED
Turn signal indicator light.................................................................... LED
Neutral indicator light.......................................................................... LED
High beam indicator light .................................................................... LED
Oil pressure/Coolant temperature/Fuel injection warning light ........... LED
6 SV1000K5/SK5

CAPACITIES
Fuel tank ............................................................................................. 16 L (4.2/3.5 US/Imp gal)................... E-33
17 L (4.5/3.7 US/Imp gal)................... Others
Engine oil, oil change......................................................................... 2 700 ml (2.9/2.4 US/Imp qt)
with filter change .............................................................. 2 900 ml (3.1/2.6 US/Imp qt)
overhaul ........................................................................... 3 300 ml (3.5/2.9 US/Imp qt)
Coolant................................................................................................ 2.2 L (2.3/1.9 US/Imp qt)

These specifications are subject to change without notice.

L E
M P
S A
 SV1000K5/SK5 7

SERVICE DATA (SV1000K5)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 36 —
(1.42)
EX. 33 —
(1.30)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem clear- IN. 0.010 – 0.046 —
ance (0.0004 – 0.0018)
EX. 0.030 – 0.066 —
(0.0012 – 0.0026)
Valve guide I.D. IN. & EX. 5.500 – 5.512 —
(0.2165 – 0.2170)
Valve stem O.D. IN. 5.475 – 5.490 —
(0.2156 – 0.2161)

Valve stem deflection

EX.

IN. & EX.

L E
5.455 – 5.470
(0.2148 – 0.2154)
—
—
0.35
(0.014)
Valve stem runout

Valve head thickness

M P IN. & EX.

IN. & EX.

—

—
0.05
(0.002)
0.5
(0.02)
Valve seat width

Valve head radial runout

Valve spring free length S A IN. & EX.

IN. & EX.

IN. & EX.

0.9 – 1.1
(0.035 – 0.043)
—

—
—
0.03
(0.001)
41.2
(1.62)
Valve spring tension 197 – 227 N
IN. & EX. (20.1 – 23.1 kgf, 44.3 – 51.0 lbs) —
at length 35.6 mm (1.40 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 37.78 – 37.82 37.48
(1.487 – 1.489) (1.476)
EX. * 37.18 – 37.22 * 36.88
(1.464 – 1.465) (1.452)
Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 0.150
(0.0007 – 0.0021) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.972 – 21.993 —
(0.8650 – 0.8659)
8 SV1000K5/SK5

ITEM STANDARD LIMIT

Camshaft runout IN. & EX. — 0.10
(0.004)
Cam drive idle gear/sprocket thrust 0.15 – 0.29 —
clearance (0.006 – 0.011)
Cylinder head distortion — 0.05
(0.002)

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

ITEM STANDARD LIMIT
Compression pressure * 1 050 – 1 450 kPa * 850 kPa
(Automatic de-comp. actuated) (10.5 – 14.5 kgf/cm2, 149 – 206 psi) (8.5 kgf/cm2, 121 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm2, 28 psi)
Piston to cylinder clearance 0.015 – 0.025 0.12
(0.0006 – 0.0010) (0.0047)
Cylinder bore 98.000 – 98.015 Nicks or
(3.8583 – 3.8589) Scratches
Piston diam. 97.980 – 97.995 97.880

E
(3.8575 – 3.8581) (3.8535)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion

Piston ring free end gap

P 1st
—

L
Approx. 8.8 (0.35)
0.05
(0.002)
7.0
(0.28)

M 2nd Approx. 10.1 (0.40) 8.1

(0.32)

A
Piston ring end gap 1st 0.15 – 0.35 0.7
(0.006 – 0.014) (0.03)

Piston ring to groove clearance

S 2nd

1st

2nd
0.30
(0.012
– 0.45
– 0.018)
—

—
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
Piston ring groove width 0.93 – 0.95 —
(0.0366 – 0.0374)
1st
1.55 – 1.57 —
(0.0610 – 0.0618)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.51 – 2.53 —
(0.0988 – 0.0996)
Piston ring thickness 0.86 – 0.91 —
(0.034 – 0.036)
1st
1.38 – 1.40 —
(0.054 – 0.055)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore I.D. 22.002 – 22.008 22.030
(0.8662 – 0.8665) (0.8673)
Piston pin O.D. 21.993 – 22.000 21.980
(0.8658 – 0.8661) (0.8654)
 SV1000K5/SK5 9

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 22.010 – 22.018 22.040
(0.8665 – 0.8668) (0.8677)
Conrod big end side clearance 0.17 – 0.32 0.50
(0.007 – 0.013) (0.020)
Conrod big end width 21.95 – 22.00 —
(0.864 – 0.866)
Crank pin width 44.17 – 44.22 —
(1.739 – 1.741)
Conrod big end oil clearance 0.040 – 0.064 0.080
(0.0016 – 0.0025) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance * – 0.004 – 0.023 0.080
(– 0.0002 – 0.0009) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft runout — 0.05
(0.002)

OIL PUMP
ITEM

L
STANDARD E LIMIT
Oil pressure (at 60 °C, 140 °F)

M P Above 350 kPa (3.5 kgf/cm2, 50 psi)

Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
—

CLUTCH
ITEM
Drive plate thickness

S A No. 1

No. 2 and 3
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
Drive plate claw width No. 1 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
No. 2 and 3 13.90 – 14.00 13.10
(0.547 – 0.551) (0.516)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 28.1 26.7
(1.11) (1.05)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5512 – 0.5528)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5505)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)
Clutch fluid type DOT 4 —
10 SV1000K5/SK5

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD LIMIT
Thermostat valve opening temper- 86.5 – 89.5 °C —
ature (188 – 193 °F)
Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm2, 15.6 psi) —
sure
Cooling fan thermo-switch operat- OFF → ON Approx. 105 °C (221 °F) —
ing temperature ON → OFF Approx. 100 °C (212 °F) —
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 alumi-
num radiator, mixed with distilled water only, at the —

E
ratio of 50:50.

L
Engine coolant Reservoir
Approx. 250 ml (0.3/0.2 US/lmp qt) —
tank side

P
Engine
Approx. 1 950 ml (2.1/1.7 US/lmp qt) —
side

DRIVE TRAIN
ITEM

AM STANDARD
Unit: mm (in) Expect ratio
LIMIT

S
Primary reduction ratio 1.838 (57/31) —
Final reduction ratio 2.352 (40/17) —
Gear ratio Low 2.666 (32/12) —
2nd 1.933 (29/15) —
3rd 1.500 (27/18) —
4th 1.227 (27/22) —
5th 1.086 (25/23) —
Top 1.000 (24/24) —
Shift fork to groove clearance 0.1 – 0.3 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type RK50SMOZ1 —
Links 110 links, ENDLESS —
20-link — 319.4
length (12.6)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 55 – 65 —
(2.2 – 2.6)
 SV1000K5/SK5 11

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount 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 Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
set pressure

FI-SENSORS
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω
CKP sensor peak voltage 5.0 V and more (When cranking)
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) Approx. 2.5 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.12 kΩ
Opened Approx. 4.26 kΩ

E
TP sensor output voltage Closed Approx. 1.12 V
Opened Approx. 4.26 V
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage

P L
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V

M
IAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage
GP switch voltage
Injector voltage

S A
Ignition coil primary peak voltage
STP sensor input voltage
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
STP sensor resistance Closed Approx. 0.58 kΩ
Opened Approx. 4.38 kΩ
STP sensor output voltage Closed Approx. 0.58 V at input voltage is 5.0 V
Opened Approx. 4.38 V at input voltage is 5.0 V
STV actuator resistance 7 – 14 Ω
Heated oxygen sensor output volt- 0.4 V and less at idle speed E-02, 19
age 0.6 V and more at 3 000 r/min E-02, 19
Heated oxygen sensor resistance 4 – 5 Ω at 23 °C (73.4 °F) E-02, 19
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
12 SV1000K5/SK5

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. * 16G4 (For E-33), 16G3 (Others)
Bore size * 54 mm
Fast idle r/min 1 900 – 2 500 r/min at 25 °C (77 °F)
Idle r/min 1 200 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Firing order 1·2
Spark plug Type NGK: CR8EK
DENSO: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Crankshaft position sensor resis- 130 – 240 Ω

E
tance Bl – G
2.8 – 4.2 Ω + tap – - tap

L
Ignition coil resistance Primary
Secondary 24 – 36 kΩ + tap –

P
Plug cap
Crankshaft position sensor peak 5.0 V and more When cranking
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output

AM 200 V and more

0.2 – 0.7 Ω
Approx. 400 W at 5 000 r/min
When cranking
Y–Y

Generator no-load voltage

(When engine is cold)
Regulated voltage
Starter relay resistance
Battery Type
S 75 V and more (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size HI 10 A
Headlight
LO 10 A
Fuel 10 A
Ignition 15 A
Turn signal 10 A
Fan motor 15 A
Main 30 A
 SV1000K5/SK5 13

WATTAGE Unit: W
ITEM SPECIFICATION
Headlight HI 60
LO 55
Position light (For E-02, 19) 5
Brake light/Taillight LED
Turn signal light 21 × 4
Speedometer/Tachometer light LED
Turn signal indicator light LED
High beam indicator light LED
Neutral indicator light LED
Fuel indicator light LED
Coolant temperature/Oil pressure/ LED
FI indicator light
License light 5

BRAKE + WHEEL Unit: mm (in)

E
ITEM STANDARD LIMIT

L
Rear brake pedal height 55 – 65 —
(2.17 – 2.56)

P
Brake disc thickness Front 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
5.0 ± 0.2 4.5

M
Rear (0.197 ± 0.008) (0.18)
Brake disc runout 0.30

A
(Front & Rear) — (0.012)

S
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6265)
Rear 14.000 – 14.043 —
(0.5512 – 0.5529)
Master cylinder piston diam. Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 13.957 – 13.984 —
(0.5495 – 0.5506)
Brake caliper cylinder Leading 30.230 – 30.280 —
bore (1.1902 – 1.1921)
Front
Trailing 33.960 – 34.010 —
(1.3370 – 1.3389)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston Leading 30.167 – 30.200 —
diam. (1.1876 – 1.1890)
Front
Trailing 33.901 – 33.934 —
(1.3346 – 1.3360)
Rear 38.115 – 38.148 —
(1.5005 – 1.5019)
Brake fluid type DOT 4 —
14 SV1000K5/SK5

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(Front & Rear) (0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 17M/C × MT 3.50 —
Rear 17M/C × MT 5.50 —
Tire size Front 120/70 ZR17M/C (58W), tubeless —
Rear 180/55 ZR17M/C (73W), tubeless —
Tire type Front MICHELIN: PILOT ROAD B —
Rear MICHELIN: PILOT ROAD B —
Tire tread depth Front — 1.6
(0.06)
Rear — 2.0

E
(0.08)

SUSPENSION
ITEM
Front fork stroke

P
STANDARD
120
(4.7)
L Unit: mm (in)
LIMIT
—
Front fork spring free length

Front fork oil level

AM 305
(12.0)

147
298
(11.7)

S
(without spring, inner tube fully (5.8) —
compressed)
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil —
Front fork oil capacity (each leg) 508 ml —
(17.2/17.9 US/lmp oz)
Front fork spring adjuster 7th groove from top —
Front fork damping force adjuster Rebound 1 and 1/4 turns out —
from stiffest position
Compres- 1 turn out from stiffest position —
sion
Rear shock absorber spring pre-set 202
(8.0) —
length
Rear shock absorber damping Rebound 3/4 turn out from stiffest position —
force adjuster Compres- 1 and 3/4 turns out
sion from stiffest position —
Rear wheel travel 130 —
(5.1)
Swingarm pivot shaft runout — 0.3
(0.01)
 SV1000K5/SK5 15

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi
FRONT 250 2.50 36 250 2.50 36
REAR 250 2.50 36 290 2.90 42

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method. Gasoline containing MTBE
E-33
(Methyl Tertiary Butyl Ether), less than 10% etha-
nol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank 16 L (4.2/3.5 US/lmp gal) E-33
17 L (4.5/3.7 US/lmp gal) The others
Engine oil type
Engine oil capacity Change
E
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA

L 2 700 ml
(2.9/2.4 US/lmp qt)

M P
Filter change

Overhaul
2 900 ml
(3.1/2.6 US/lmp qt)
3 300 ml
(3.5/2.9 US/lmp qt)

S A
16 SV1000K5/SK5

SERVICE DATA (SV1000SK5)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 36 —
(1.42)
EX. 33 —
(1.30)
Tappet clearance (when cold) IN. 0.10 – 0.20 —
(0.004 – 0.008)
EX. 0.20 – 0.30 —
(0.008 – 0.012)
Valve guide to valve stem clear- IN. 0.010 – 0.046 —
ance (0.0004 – 0.0018)
EX. 0.030 – 0.066 —
(0.0012 – 0.0026)
Valve guide I.D. IN. & EX. 5.500 – 5.512 —
(0.2165 – 0.2170)
Valve stem O.D. IN. 5.475 – 5.490 —
(0.2156 – 0.2161)

E
EX. 5.455 – 5.470 —
(0.2148 – 0.2154)
Valve stem deflection

Valve stem runout

IN. & EX.

P
IN. & EX.
—

— L 0.35
(0.014)
0.05
(0.002)
Valve head thickness

Valve seat width

AM
IN. & EX.

IN. & EX.

—
0.9 – 1.1
(0.035 – 0.043)
0.5
(0.02)
—
Valve head radial runout

Valve spring free length

Valve spring tension

S
IN. & EX.

IN. & EX.

IN. & EX.

—

—
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
0.03
(0.001)
41.2
(1.62)

—
at length 35.6 mm (1.40 in)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 37.78 – 37.82 37.48
(1.487 – 1.489) (1.476)
EX. * 37.18 – 37.22 * 36.88
(1.464 – 1.465) (1.452)
Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 0.150
(0.0007 – 0.0021) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.972 – 21.993 —
(0.8650 – 0.8659)
 SV1000K5/SK5 17

ITEM STANDARD LIMIT

Camshaft runout IN. & EX. — 0.10
(0.004)
Cam drive idle gear/sprocket thrust 0.15 – 0.29 —
clearance (0.006 – 0.011)
Cylinder head distortion — 0.05
(0.002)

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

ITEM STANDARD LIMIT
Compression pressure * 1 050 – 1 450 kPa * 850 kPa
(Automatic de-comp. actuated) (10.5 – 14.5 kgf/cm2 , 149 – 206 psi) (8.5 kgf/cm2, 121 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm 2, 28 psi)
Piston to cylinder clearance 0.015 – 0.025 0.12
(0.0006 – 0.0010) (0.0047)
Cylinder bore 98.000 – 98.015 Nicks or
(3.8583 – 3.8589) Scratches
Piston diam. 97.980 – 97.995

E
(3.8575 – 3.8581) 97.880
Measure at 10 mm (0.4 in) from the skirt end. (3.8535)
Cylinder distortion

Piston ring free end gap

P 1st
—

L
Approx. 8.8 (0.35)
0.05
(0.002)
7.0
(0.28)

Piston ring end gap

AM 2nd

1st
Approx. 10.1 (0.40)
0.15 – 0.35
(0.006 – 0.014)
8.1
(0.32)
0.7
(0.03)

S
Piston ring to groove clearance
2nd

1st

2nd
0.30 – 0.45
(0.012 – 0.018)
—

—
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
Piston ring groove width 0.93 – 0.95 —
(0.0366 – 0.0374)
1st
1.55 – 1.57 —
(0.0610 – 0.0618)
2nd 1.01 – 1.03 —
(0.0398 – 0.0406)
Oil 2.51 – 2.53 —
(0.0988 – 0.0996)
Piston ring thickness 0.86 – 0.91 —
(0.034 – 0.036)
1st
1.38 – 1.40 —
(0.054 – 0.055)
2nd 0.97 – 0.99 —
(0.038 – 0.039)
Piston pin bore I.D. 22.002 – 22.008 22.030
(0.8662 – 0.8665) (0.8673)
Piston pin O.D. 21.993 – 22.000 21.980
(0.8658 – 0.8661) (0.8654)
18 SV1000K5/SK5

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 22.010 – 22.018 22.040
(0.8665 – 0.8668) (0.8677)
Conrod big end side clearance 0.17 – 0.32 0.50
(0.007 – 0.013) (0.020)
Conrod big end width 21.95 – 22.00 —
(0.864 – 0.866)
Crank pin width 44.17 – 44.22 —
(1.739 – 1.741)
Conrod big end oil clearance 0.040 – 0.064 0.080
(0.0016 – 0.0025) (0.0031)
Crank pin O.D. 44.976 – 45.000 —
(1.7707 – 1.7717)
Crankshaft journal oil clearance * – 0.004 – 0.023 0.080
(– 0.0002 – 0.0009) (0.0031)
Crankshaft journal O.D. 47.985 – 48.000 —
(1.8892 – 1.8898)
Crankshaft runout — 0.05
(0.002)

OIL PUMP

L E
P
ITEM STANDARD LIMIT
Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)

M
—
at 3 000 r/min

CLUTCH
ITEM
Drive plate thickness
S A No. 1
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
No. 2 and 3 (0.146 – 0.153) (0.135)
Drive plate claw width No. 1 13.85 – 13.96 13.05
(0.545 – 0.550) (0.514)
No. 2 and 3 13.90 – 14.00 13.10
(0.547 – 0.551) (0.516)
Driven plate distortion — 0.10
(0.004)
Clutch spring free length 28.1 26.7
(1.11) (1.05)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5512 – 0.5528)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5505)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)
Clutch fluid type DOT 4 —
 SV1000K5/SK5 19

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM STANDARD LIMIT
Thermostat valve opening temper- 86.5 – 89.5 °C —
ature (188 – 193 °F)
Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —
Radiator cap valve opening pres- 110 kPa (1.1 kgf/cm2, 15.6 psi) —
sure
Cooling fan thermo-switch operat- OFF → ON Approx. 105 °C (221 °F) —
ing temperature ON → OFF Approx. 100 °C (212 °F) —
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 alumi-
num radiator, mixed with distilled water only, at the —

Engine coolant
ratio of 50:50.
Reservoir
tank side

L E
Approx. 250 ml (0.3/0.2 US/lmp qt) —

DRIVE TRAIN
M PEngine
side
Approx. 1 950 ml (2.1/1.7 US/lmp qt) —

Unit: mm (in) Expect ratio

ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio S A Low
STANDARD
1.838 (57/31)
2.352 (40/17)
2.666 (32/12)
LIMIT
—
—
—
2nd 1.933 (29/15) —
3rd 1.500 (27/18) —
4th 1.227 (27/22) —
5th 1.086 (25/23) —
Top 1.000 (24/24) —
Shift fork to groove clearance 0.1 – 0.3 0.50
(0.004 – 0.012) (0.020)
Shift fork groove width 5.0 – 5.1 —
(0.197 – 0.201)
Shift fork thickness 4.8 – 4.9 —
(0.189 – 0.193)
Drive chain Type RK50SMOZ1 —
Links 108 links, ENDLESS —
20-link — 319.4
length (12.6)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 55 – 65 —
(2.2 – 2.6)
20 SV1000K5/SK5

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM SPECIFICATION NOTE
Injector resistance 11 – 13 Ω at 20 °C (68 °F)
Fuel pump discharge amount 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 Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
set pressure

FI-SENSORS
ITEM SPECIFICATION NOTE
CKP sensor resistance 130 – 240 Ω
CKP sensor peak voltage 5.0 V and more (When cranking)
IAP sensor input voltage (F & R) 4.5 – 5.5 V
IAP sensor output voltage (F & R) Approx. 2.5 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor resistance Closed Approx. 1.12 kΩ
Opened Approx. 4.26 kΩ

E
TP sensor output voltage Closed Approx. 1.12 V

L
Opened Approx. 4.26 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance

M P Approx. 2.45 kΩ at 20 °C (68 °F)

4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)

A
TO sensor resistance 19.1 – 19.7 kΩ
TO sensor voltage 1.4 V and less
GP switch voltage
Injector voltage

STP sensor input voltage

STP sensor resistance
S
Ignition coil primary peak voltage

Closed
0.6 V and more (From 1st to top)
Battery voltage
200 V and more (When cranking)
4.5 – 5.5 V
Approx. 0.58 kΩ
Opened Approx. 4.38 kΩ
STP sensor output voltage Closed Approx. 0.58 V at input voltage is 5.0 V
Opened Approx. 4.38 V at input voltage is 5.0 V
STV actuator resistance 7 – 14 Ω
Heated oxygen sensor output volt- 0.4 V and less at idle speed E-02, 19
age 0.6 V and more at 3 000 r/min E-02, 19
Heated oxygen sensor resistance 4 – 5 Ω at 23 °C (73.4 °F) E-02, 19
PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)
 SV1000K5/SK5 21

THROTTLE BODY
ITEM SPECIFICATION
I.D. No. * 16G4 (For E-33), 16G3 (For others)
Bore size * 54 mm
Fast idle r/min 1 900 – 2 500 r/min at 25 °C (77 °F)
Idle r/min 1 200 ± 100 r/min/Warmed engine
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Firing order 1·2
Spark plug Type NGK: CR8EK
DENSO: U24ETR
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Crankshaft position sensor resis-

E
tance 130 – 240 Ω Bl – G

L
Ignition coil resistance Primary 2.8 – 4.2 Ω + tap – - tap
Secondary 24 – 36 kΩ + tap – Plug cap
Crankshaft position sensor peak
voltage

M P
Ignition coil primary peak voltage
Generator coil resistance
5.0 V and more
200 V and more
0.2 – 0.7 Ω
When cranking
When cranking
Y–Y
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance S A Approx. 400 W at 5 000 r/min
75 V and more (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
Battery Type FTX14-BS
designation
Capacity 12 V 43.2 kC (12 Ah)/10 HR
Fuse size HI 15 A
Headlight
LO 15 A
Fuel 10 A
Ignition 15 A
Turn signal 10 A
Fan motor 15 A
Main 30 A
22 SV1000K5/SK5

WATTAGE Unit: W
ITEM SPECIFICATION
Headlight HI 60 × 2
LO 55 × 2
Position light 5×2
Brake light/Taillight LED
Turn signal light 21 × 4
Speedometer/Tachometer light LED
Turn signal indicator light LED
High beam indicator light LED
Neutral indicator light LED
Fuel indicator light LED
Coolant temperature/oil pressure/ LED
FI indicator light
License light 5

BRAKE + WHEEL Unit: mm (in)

ITEM
Rear brake pedal height
STANDARD
55 – 65
(2.17 – 2.56)

L E LIMIT
—

P
Brake disc thickness
Front 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)

M
Rear 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)

A
Brake disc runout 0.30
(Front & Rear) — (0.012)

S
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6265)
Rear 14.000 – 14.043 —
(0.5512 – 0.5529)
Master cylinder piston diam. Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 13.957 – 13.984 —
(0.5495 – 0.5506)
Brake caliper cylinder Leading 30.230 – 30.280 —
bore (1.1902 – 1.1921)
Front
Trailing 33.960 – 34.010 —
(1.3370 – 1.3389)
Rear 38.180 – 38.230 —
(1.5031 – 1.5051)
Brake caliper piston
Leading 30.167 – 30.200 —
diam. (1.1876 – 1.1890)
Front
Trailing 33.901 – 33.934 —
(1.3346 – 1.3360)
Rear 38.115 – 38.148 —
(1.5005 – 1.5019)
Brake fluid type DOT 4 —
 SV1000K5/SK5 23

ITEM STANDARD LIMIT

Wheel rim runout
Axial — 2.0
(Front & Rear) (0.08)
Radial — 2.0
(0.08)
Wheel axle runout
Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 17 × MT 3.50, 17M/C × MT 3.50 —
Rear 17 × MT 5.50, 17M/C × MT 5.50 —
Tire size Front 120/70 ZR17M/C (58W), tubeless —
Rear 180/55 ZR17M/C (73W), tubeless —
Tire type Front MICHELIN: PILOT SPORT E —
Rear MICHELIN: PILOT SPORT L —
Tire tread depth Front — 1.6
(0.06)
Rear — 2.0

E
(0.08)

SUSPENSION
ITEM
Front fork stroke
P
STANDARD
115L Unit: mm (in)
LIMIT
—

M
(4.5)
Front fork spring free length * 260.2 * 254

A
(10.24) (10.0)
Front fork oil level

S
(without spring, inner tube fully * 140 —
(5.5)
compressed)
Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil —
Front fork oil capacity (each leg) * 565 ml —
(19.1/19.9 US/lmp oz)
Front fork spring adjuster 6th groove from top —
Front fork damping force adjuster Rebound * 1 and 1/4 turn out —
from stiffest position
Compres- 1 turn out from stiffest position —
sion
Rear shock absorber spring pre-set 199.3
(7.85) —
length
Rear shock absorber damping Rebound 3/4 turn out from stiffest position —
force adjuster Compres- 2 and 1/4 turns out
sion from stiffest position —
Rear wheel travel 130 —
(5.1)
Swingarm pivot shaft runout — 0.3
(0.01)
24 SV1000K5/SK5

TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi
FRONT 250 2.50 36 250 2.50 36
REAR 250 2.50 36 290 2.90 42

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method. Gasoline containing MTBE
E-03, 28, 33
(Methyl Tertiary Butyl Ether), less than 10% etha-
nol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
The others
higher. An unleaded gasoline is recommended.
Fuel tank 16 L (4.2/3.5 US/lmp gal) E-33

E
17 L (4.5/3.7 US/lmp gal) The others
Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change

P
Filter change L
2 700 ml
(2.9/2.4 US/lmp qt)
2 900 ml
(3.1/2.6 US/lmp qt)

AM
Overhaul 3 300 ml
(3.5/2.9 US/lmp qt)

S
 SV1000K5/SK5 25

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 I.D. specification Bearing
52.000 – 52.006 mm
A Green
(2.0472 – 2.0475 in)
52.006 – 52.012 mm
B Black
(2.0475 – 2.0477 in)
52.012 – 52.018 mm
C Brown
(2.0477 – 2.0479 in)

Bearing thickness Color code

Color (Part No.) Thickness

Green 1.999 – 2.002 mm
(12229-16G00-0A0) (0.0787 – 0.0788 in)
Black
(12229-16G00-0B0)
Brown
2.002 – 2.005 mm
(0.0788 – 0.0789 in)
2.005 – 2.008 mm

L E
!
(12229-16G00-0C0)

M P (0.0789 – 0.0791 in)

A
Bearing must be replaced as a set.

S
26 SV1000K5/SK5

FI SYSTEM WIRING DIAGRAM

(For E-02, 19)

L E
M P
S A
 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 TERMINAL
CIRCUIT CIRCUIT
NO. NO.
1 Front cylinder ignition coil (IG1) M HO2 control selector (EXS) For E-02, 19
2 Rear cylinder ignition coil (IG2) N HO2 sensor signal (HO2S) For E-02, 19
3 Ground (E3) O —
4 Serial data for tachometer (TACO) P CKP sensor signal (CKP+)
5
6
7
Front cylinder fuel injector (#1)
Rear cylinder fuel injector (#2)
PAIR control solenoid valve (PAIR)
Q
R
S
L E —
Power source for fuel injector (VM)
—
8
9
0

M P
HO2 sensor heater (HO2) For E-02, 19
Power source for back-up (B+2)
Power source for sensors (VCC)
T
U
V
CKP sensor signal (CKP–)
GP switch signal (GP)
Fuel pump relay (FP Relay)

A
A — W Ignition switch signal (AT)
B CMP sensor signal (CMPS) X Sensor ground (E2)
C
D
E
F
G
S
ECM ground (E1)
IAT sensor signal (IAT)
Power source (B+1)
IAP sensor signal (IAPS)
ATM pressure sensor signal (APS)
Y
Z
[
\
]
Ground (E1)
ECT sensor signal (ECT)
Serial data for speedometer (TECH)
—
—
H Clutch lever position switch (CLP) ^ Neutral switch (NT)
I TP sensor signal (TP) a TO sensor signal (TOS)
J Actuator motor (+) b —
K Starter switch (STA) c —
L Actuator motor (–) d STP sensor signal (STP)
28 SV1000K5/SK5

ECM TERMINAL (For K5-Model)

TERMINAL TERMINAL
CIRCUIT CIRCUIT
NO. NO.
1 — H —
2 — I —
3 Actuator motor (–) J —
4 Actuator motor (+) K Blank
5
6
7
STP sensor signal (STP)
Serial data for speedometer (TECH)
Blank
L
M
N E
TO sensor signal (TOS)

L
GP switch signal (GP)
Blank
8
9
0
TP sensor signal (TP)

M P
IAP sensor signal (Front) (IAPS)
ECT sensor signal (ECT)
O
P
Q
Blank
IAP sensor signal (Rear) (IAPS)
IAT sensor signal (IAT)

A
A Power source for sensor (VCC) R Blank
B HO2 sensor signal (HO2S) For E-02, 19 S Sensor ground (E2)
C
D
E
F
G
Blank

S
CKP sensor signal (CKP+)
Ignition switch signal (AT)
Power source for back-up (B+2)
Power source (B+1)
T
U
V
W
X
Blank
CKP sensor signal (CKP–)
—
Power source for fuel injector (VM)
ECM ground (E1)

TERMINAL
CIRCUIT
NO.
Y HO2 sensor heater (HO2, H) For E-02, 19
Z Blank
[ Serial data for tachometer (TACO)
\ Fuel pump relay (FP Relay)
] Blank
^ PAIR control solenoid valve (PAIR)
a Rear cylinder fuel injector (#2)
b Front cylinder fuel injector (#1)
c Front cylinder ignition coil (IG1)
TERMINAL
CIRCUIT
NO.
d —
e HO2 control selector (EXS) For E-02, 19
f —
g Neutral switch (NT)
h Clutch lever position switch (CLP)
i Starter switch (STA)
j Ground (E3)
k Ground (E1)
l 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 mini-
mum performance necessary even under malfunction condition.

STARTING RUNNING
ITEM FAIL-SAFE MODE
ABILITY ABILITY
Intake air pressure sensor Intake air pressure is fixed to
“YES” “YES”
(Front & Rear) 760 mmHg.
Throttle position sensor TPS opening value is fixed to full
“YES” “YES”
open position.
Engine coolant temp. sensor Engine coolant temperature value is
“YES” “YES”
fixed to 80 °C.
Intake air temperature sensor Intake air temperature value is fixed
“YES” “YES”
to 40 °C.
Ignition signal #1 (IG coil #1) #1 Ignition-off and #1 Fuel-cut “YES” “YES”
#2 cylinder can run.
Ignition signal #2 (IG coil #2) #2 Ignition-off and #2 Fuel-cut “YES” “YES”
#1 cylinder can run.
Injection signal #1

Injection signal #2
#1 Fuel-cut

#2 Fuel-cut

L E “YES”
#2 cylinder can
“YES”
“YES”
run.
“YES”

HO2 sensor (For E-02, 19)

M P
Feedback compensation is inhibited.
(Air/fuel ratio is fixed to normal.)
#1 cylinder can

“YES”
run.

“YES”

A
Secondary throttle valve Secondary throttle valve is fixed in
“YES” “YES”
actuator any position.
Secondary throttle position
sensor
Gear position signal

PAIR control solenoid valve

S Secondary throttle valve is fixed in
full close position.
Gear position signal is fixed to 6th
gear.
O2 feedback control is stopped and
“YES”

“YES”

“YES”
“YES”

“YES”

“YES”
PAIR valve is fixed to open position.

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 nec-
essary to bring the motorcycle to the workshop for complete repair.
30 SV1000K5/SK5

MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION DETECTED FAILURE CONDITION
DETECTED ITEM
CODE CHECK FOR
C00 NO FAULT ——————
Crankshaft position The signal does not reach ECM for more than 2 sec. after
sensor receiving the starter signal.
C12
The crankshaft position sensor wiring and mechanical parts
(Crankshaft position sensor, wiring/coupler connection)
Intake air pressure When incorrect vacuum hose and/or lead wire coupler connec-
sensor (Front) tion, C13 is indicated.
The sensor should produce following voltage.
C13
(0.50 V sensor voltage < 4.85 V)
Without the above range, C13 is indicated.
Intake air pressure sensor, wiring/coupler connection
Throttle position sen- The sensor should produce following voltage.
sor (0.20 V sensor voltage < 4.80 V)
C14
Without the above range, C14 is indicated.

Engine coolant tem-

perature sensor

L E
Throttle position sensor, wiring/coupler connection
The sensor voltage should be the following.
(0.15 V sensor voltage < 4.85 V)

P
C15
Without the above range, C15 is indicated.
Engine coolant temperature sensor, wiring/coupler connection

sensor (Rear)

AM
Intake air pressure When incorrect vacuum hose and/or lead wire coupler connec-
tion, C17 is indicated.
The sensor should produce following voltage.

S
C17
(0.50 V sensor voltage < 4.85 V)
Without the above range, C17 is indicated.
Intake air pressure sensor, wiring/coupler connection
Intake air temperature The sensor voltage should be the following.
sensor (0.15 V sensor voltage < 4.85 V)
C21
Without the above range, C21 is indicated.
Intake air temperature sensor, wiring/coupler connection
Tip over sensor The sensor voltage should be the following for more than 2 sec.
after ignition switch turns ON.
C23 (0.20 V sensor voltage < 4.80 V)
Without the above value, C23 is indicated.
Tip over sensor, wiring/coupler connection
Ignition signal Crankshaft position sensor signal is produced and ECM deter-
mines the ignition signal but signal from ignition coil is inter-
rupted continuous by 4 times or more. In this case, the code
C24 or C25
C24 or C25 is indicated.
Ignition coil, wiring/coupler connection, power supply from the
battery
 SV1000K5/SK5 31

Secondary throttle When no actuator control signal is supplied from the ECM,
valve actuator communication signal does not reatch ECM or operation volt-
C28 age does not reach STVA motor, C28 is indicated. STVA can
not operate.
STVA lead wire/coupler, STVA
Secondary throttle The sensor should produce following voltage.
valve position sensor (0.10 V sensor voltage < 4.90 V)
C29
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)
C31
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 deter-
mines the injection signal but fuel injection signal is interrupted

E
C32 or C33 continuous by 4 times or more. In this case, the code C32 or
C33 is indicated.

P
Fuel pump relay
L
Injector, wiring/coupler connection, power supply to the injector
No voltage is applied to fuel pump although fuel pump relay is
turned ON, or voltage is applied to fuel pump although fuel

M
C41 pump relay is turned OFF.
Fuel pump relay, connecting lead, power source to fuel pump

C42

S A
Ignition switch
relay
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
C44
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
C49 valve (PAIR valve) indicated. PAIR valve can not operate.
PAIR valve lead wire/coupler
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 continu-
ity 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)

L E
M P
“C13” or “C17” IAP SENSOR CIRCUIT MALFUNCTION

A
3
ECM coupler (Wiring harness side)

S
“C14” TP SENSOR CIRCUIT MALFUNCTION
3
ECM coupler (Wiring harness side)
 SV1000K5/SK5 33

“C15” ECT SENSOR CIRCUIT MALFUNCTION

2
ECM coupler (Wiring harness side)

“C21” IAT SENSOR CIRCUIT MALFUNCTION

2
ECM coupler (Wiring harness side)

L E
M P
S A
“C23” TO SENSOR CIRCUIT MALFUNCTION
2
ECM coupler (Wiring harness side)

“C28” STV ACTUATOR CIRCUIT MALFUNCTION

2
ECM coupler (Wiring harness side)
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)

L E
M P
S A
“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 35

“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)

L E
M P
S A
36 SV1000K5/SK5

FRONT FORK (For SV1000SK5)

 O-ring
! Spacer
Washer

" Spring
# Inner rod/Damper rod
$ Inner tube
(Cartridge)

% Protector
& Dust seal
' Oil seal stopper ring
 Oil seal
) Oil seal retainer
* Guide metal
+ Slide metal
, Oil lock piece
L E
- Outer tube
. Gasket
) Front fork cap bolt
M P
* Inner rod lock nut
+ Front axle pinch bolt
, Damper rod bolt
(
ITEM N·m kgf-m lb-ft
S A
) 23 2.3 16.5
* 15 1.5 11.5
+ 23 2.3 16.5
, 23 2.3 16.5

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 ON
ON
indicator switch as shown in the right illustrations. The bulb Battery Battery
should come on after several seconds if the switch is in good Test
condition. bulb
Test
bulb

When the switch is immersed in kerosine under the above con- OFF
OFF
dition, the bulb should go out. If the bulb remains lit, replace the Battery Battery
unit with a new one. Test
Test bulb
! bulb

* When the light turns off, immediately pick up the

switch from kerosene.
* After the check has been completed, wash the switch
with gasoline.

L E Kerosine
Kerosine

M P
S A
38 SV1000K5/SK5

WIRING HARNESS ROUTING (For SV1000K5)

Generator lead UPPER Clamp

Wiring harness
Wiring harness
Generator
Set the coupler
center of the frame.

Ignition coil
Set the speed sensor
coupler under the
clutch hose.

L E
M P
Throttle cables
Wiring harness

Handle switch (L) Side stand switch

Generator
Side stand switch
Clutch hose

Cable guide

S A
Clamp the lead wire
Clamp

Clamp
Speed sensor

Clamp
Clamp
Handle switch (R)
Ignition switch

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 Don’t slacken. Clamp

harness between the Harness
frame and reservoir tank. Set surely. Rear turn signal light (L)

E
Licence lamp

P L
AM
S
Taping clamp
Set “ ” mark exhaust side.
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

Wiring harness
Turn signal (RH, LH)

Speedometer wire
40 SV1000K5/SK5

THROTTLE CABLE ROUTING (For SV1000K5)

Throttle cable No. 1

Throttle cable No. 2 Brake hose

Guide Pass the throttle cables

in front of the brake hose.

Throttle cable No. 1

Harness

Throttle cable No. 2

Handle switch
(LH)

Guide
VIEW B Clutch hose

E
Clamp

P B L
AM A
Throttle cable No. 1

Pass the throttle cable No. 1

SECT A – A

S
upper the No. 2.
Throttle cable No. 2

Guide
0 mm

A Harness

0 mm

Handle switch
(LH)

Clutch hose
 SV1000K5/SK5 41

THROTTLE BODY INSTALLATION/HOSE ROUTING

Intake pipe side Air cleaner side
Forward Forward

Breather Marking
15 – 25˚ 15 – 25˚ 15 – 25˚ hose (White)
Purge hose (E-33)

Marking (Yellow)

Purge hose
(E-33 only)
Clamp
Pass the vacuum hose
Don’t touch the high tension cord upward of the PAIR hose.
and purge hose. Intake air pressure

E
sensor #1
PAIR air
vent hose

P L
Wiring harness

AM
0 – 20˚
Frame

S
Water guard
plate

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)
 42

Face the clamp ends backward.

After positioning the clamp with the stopper,
tighten the clamp bolt.

Be careful not to contact C

SV1000K5/SK5

the seat rail and reservoir

tank, when installing.

The white paint faces outside.

A

VIEW A
Face the clamp ends backward.

VIEW B

Insert the hose until dead end.

B

S
After the brake hose union touching
to the stopper, tighten the union bolt.

A
The white paint faces outside.

M
35˚ 35˚

P
After the brake hose
union touching to
the stopper,
REAR BRAKE HOSE ROUTING (For SV1000K5)

L E tighten the union bolt.

VIEW C
 Face the clamp ends backward.
After positioning the clamp with the stopper,
tighten the clamp bolt.

Be careful not to contact C

the seat rail and reservoir
tank, when installing.

The white paint faces outside.

A

VIEW A
Face the clamp ends backward.

S
VIEW B

Insert the hose until dead end.

B

A
After the brake hose union touching
to the stopper, tighten the union bolt.

The white paint faces outside.

M P
28˚ 35˚
L After the brake hose
union touching to
the stopper,
tighten the union bolt.
REAR BRAKE HOSE ROUTING (For SV1000SK5)

E
VIEW C
SV1000K5/SK5
43
 Prepared by

L E
M P December, 2004

S A
Part No. 99501-39560-01E
Printed in Japan

44
WIRING DIAGRAM
SV1000K5 (For E-02, 19)
OIL
R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R) PRESSURE
L : TURN SIGNAL INDICATOR LIGHT (L) L R HAZARD ENGINESTOP STARTER FRONT BRAKE SWITCH
B : HI-BEAM INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH
N : NEUTRAL INDICATOR LIGHT N SPEEDOMETER B OFF OFF OFF
OFF
F : FUEL LEVEL INDICATOR LIGHT IGNITION SWITCH ON RUN PUSH ON
HO2 ON
O F ECM
O : OIL, TEMP., FI INDICATOR LIGHT ON SENSOR FUEL
REAR BRAKE TO
RESISTOR OFF PUMP
LOCK
SWITCH FUEL PUMP SENSOR
P RELAY
ON
M

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl
Lg
IGNITION IGNITION OFF

Gr
W

W
B
O/Y
Br
O
R
COIL #1 COIL #2

B/Lg
B/W

R/B
Y/R
W

W/B
R
B

Gr/W
Br/W

Br/W
B/Br
W/Bl

Bl/W

Bl/W
Gr/B

Gr/R
B/Br

Gr/R
B/Br

Br/B

B/Br
O/W

Bl/G

G/Bl

Bl/G
R/W

Bl/B

W/G

B/Bl

Bl/R

Bl/B

Bl/R
B/W
B/W

W/R

B/W

W/B
B/W

R/W

Bl/Y

Bl/Y

W/R

B/W
P/W
O/G

O/G
O/R

G/B

B/G
Y/B

Y/R

Y/G

B/R
R/B
B/Y

Y/B

Y/R

P/B
Dg
Br
Bl

G
R

R
P

Y
B/Lg

Br/B
Bl/B

R/W

B/W

B/W

B/Lg
P/W
O/G

O/R

B/G

O/R
G/Y

R/B

B/R
O/G
R/B

B/Lg
Lg

W/Bl

B/W
Br

W/B
O/W

B/Br
O/W

R/B

O/G
W/B

Y/R
Y/W

O/W

W/G
O/G

W/B
O

B/O
B

G/Y
O/B
Y

Y/G
Lbl
Lg

B
B
E
LICENSE LIGHT
Br B
B/W B

L
FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B
B/W B/W B/W B/W

P
BRAKE LIGHT/TAILLIGHT
HEADLIGHT
Y Br Gr
B/W B/W B/W

M
W
B/Bl W/B W/B

B BB B B

A
B/W B/W
B/W B/W B/W

FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

S
Br
B Br
B
B/W
B/W B/W
B/W
POSITION LIGHT

B/W
W/Bl
B/W

Y/Bl
B/W
Y/W
O/G

B/Y

B/Br

Gr/W
Lbl

B/Br

B/Br
Gr/B

B/Br
B/Br

W/Bl

B/Br

G/Bl
O/Bl
Lg

B/Bl

B/W

Bl/B

B/W

B/W
B/W
O/Bl

G/B

P/W

B/W
O/B
B/W

P/B

Y/Bl

R/W

P/W
O/Y

O/W
R/B
B/R

B/R
B/R
O/G

O/R
Y/R

Y/G
B/R
B/R
B/Y
B/R

O/Y

Lbl
B

Dg
Br
Bl
R
Y

Bl

B
B
B
B
B
Br
R

G
W

G
P

B
B
B
B
B
B
R
O
Y

B/W
HORN

B/W
B/W
B/R
B/R
B/W

Bl
G

Y
Y
Y

B
B
B
G
4 5 6
B/R

Bl
Bl
B/W

R
B
O/G

B/W
B/Y
B/Y

Y
Bl
Lbl

B/R
Lg

B
B
O
B

B
IAP IAP 1
Gr/W
Gr/B
R/B
B/R
Y/R

B/R
SENSOR SENSOR TP
STP ECT 1 2 3 SENSOR
ON #1 #2 IAT
SENSOR SENSOR SPEEDOMETER REGULATOR/ 1: MAIN 30 A
OFF SENSOR GENERATOR RECTIFIER BATTERY
GEAR SENSOR STARTER
L HI FREE FAN MOTOR POSITION PAIR RELAY
PUSH PUSH PUSH LO FAN FUSE BOX SORENOID
SWITCH SWITCH
Gr/W
Gr/B
R/B
B/R

Y/R

Y/R

HORN R
PASSING DIMMER CLUTCH MOTOR 1. HEAD HI 10 A VALVE FREE
STARTER
2. HEAD LO 10 A PUSH
BUTTON TURN SIGNAL LIGHT SWITCH LEVER MOTOR
SWITCH 3. FUEL 10 A
SWITCH POSITION 4. IGNITION 15 A SIDE-STAND
SWITCH 5. SIGNAL 10 A SWITCH
6. FAN 15 A
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2 #1
INJECTOR
SV1000K5 (For E-24, 33)
R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R)
L R OIL
L : TURN SIGNAL INDICATOR LIGHT (L) HAZARD ENGINESTOP STARTER FRONT BRAKE PRESSURE
B : HI-BEAM INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH SWITCH
N : NEUTRAL INDICATOR LIGHT N SPEEDOMETER B OFF OFF OFF
F : FUEL LEVEL INDICATOR LIGHT IGNITION SWITCH ON RUN PUSH ON
O F OFF
ECM
O : OIL, TEMP., FI INDICATOR LIGHT ON FUEL
ON REAR BRAKE TO
RESISTOR OFF PUMP
LOCK
SWITCH FUEL PUMP SENSOR
P RELAY
ON
M

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl
Lg
IGNITION IGNITION OFF

B
O/Y
Br
O
R
COIL #1 COIL #2

B/Lg
B/W

R/B
Y/R
W

W/B
R
B

Gr/W
Br/W

Br/W
B/Br
W/Bl

Bl/W

Bl/W
Gr/B

Gr/R
B/Br

Gr/R
Br/B

B/Br
O/W

Bl/G

G/Bl

Bl/G
R/W

Bl/B

O/W

B/Bl

Bl/R

Bl/B

Bl/R

O/W
B/W
B/W

W/R

B/W

B/W

R/W

Bl/Y

Bl/Y

W/R

B/W
P/W
O/R

G/B

B/G
Y/B

Y/R

Y/G

B/R
R/B
B/Y

Y/B

Y/R

P/B
Dg
Br
Bl

G
R

R
P

Y
B/Lg

Br/B
Bl/B

R/W

B/W

B/W

B/Lg
P/W
O/G

O/R

B/G

O/R
G/Y

R/B

B/R
O/G
R/B

B/Lg
Lg

W/Bl

B/W
Br

W/B
O/W

O/W

R/B

O/G
W/B

Y/R
Y/W
O/G
O

B/O
B

G/Y
O/B
Y

Y/G
Lbl
Lg

B
B
LICENSE LIGHT
Br B

E
B/W B
FRONT TURN SIGNAL LIGHT (R)
REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B

L
B/W B/W B/W B/W

BRAKE LIGHT/TAILLIGHT
HEADLIGHT

P
Y Br Gr
B/W B/W B/W
W
B/Bl W/B W/B

M
B B B B
B/W B/W B/W B/W
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

S A

B/W
W/Bl
B/W

Y/Bl
B/W
Y/W
O/G

B/Y

B/Br

Gr/W
Lbl

B/Br

B/Br
Gr/B

B/Br
B/Br

W/Bl

B/Br

G/Bl

B/W
B/W
O/Bl
Lg

B/Bl

B/W

Bl/B

B/W
O/Bl

G/B

P/W

B/W
O/B
B/W

B/R
B/R
P/B

Y/Bl

R/W

P/W
O/Y

O/W
R/B
B/R

O/G

O/R
Y/R

B/R

O/Y

Lbl
B

Y/G
B/R
B/R
B/Y
Dg
Br
Bl
R
Y

Bl

Br
R

B
B
B
G
W

G
P

B
B
B
R
O
Y

B/W
HORN

B/W
B/W
B/R
B/R
B/W

Bl
G

B
B
B
Y
Y
Y
G
4 5 6
B/R

Bl
Bl
B/W

R
B
O/G

B/W
B/Y
B/Y

Y
Bl
Lbl

B/R
Lg

B
B
O
B

B
IAP IAP 1
Gr/W
Gr/B
R/B
B/R
Y/R

B/R SENSOR SENSOR TP

STP 1 2 3
ON
#1 #2 ECT IAT SENSOR
SENSOR REGULATOR/ 1: MAIN 30 A
OFF SENSOR SENSOR SPEEDOMETER GENERATOR RECTIFIER BATTERY
GEAR STARTER
POSITION SENSOR
L HI FREE FAN MOTOR FUSE BOX RELAY
PUSH PUSH PUSH LO SWITCH FAN SWITCH PAIR
Gr/W
Gr/B
R/B
B/R

Y/R

Y/R

HORN R
PASSING DIMMER CLUTCH MOTOR 1. HEAD HI 10 A SORENOID FREE
STARTER
2. HEAD LO 10 A PUSH
BUTTON TURN SIGNAL LIGHT SWITCH LEVER VALVE MOTOR
SWITCH 3. FUEL 10 A
SWITCH POSITION 4. IGNITION 15 A SIDE-STAND
SWITCH 5. SIGNAL 10 A SWITCH
6. FAN 15 A
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2 #1
INJECTOR
SV1000SK5 (For E-02, 19)

OIL
R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R) PRESSURE
L : TURN SIGNAL INDICATOR LIGHT (L) L R HAZARD ENGINESTOP STARTER FRONT BRAKE SWITCH
B : HI-BEAM INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH
N : NEUTRAL INDICATOR LIGHT N SPEEDOMETER B OFF OFF OFF
OFF
F : FUEL LEVEL INDICATOR LIGHT IGNITION SWITCH ON RUN PUSH ON
ON
O F HO2 ECM
O : OIL, TEMP., FI INDICATOR LIGHT ON SENSOR FUEL
REAR BRAKE TO
RESISTOR OFF PUMP
LOCK
SWITCH FUEL PUMP SENSOR
P RELAY
ON
M

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl
Lg
IGNITION IGNITION OFF

Gr
W

W
B
O/Y
Br
O
R
COIL #1 COIL #2

B/Lg
B/W

R/B
Y/R
W

W/B
R
B

Gr/W
Br/W

Br/W
B/Br
W/Bl

Bl/W

Bl/W
Gr/B

Gr/R
B/Br

Gr/R
B/Br

Br/B

B/Br
O/W

Bl/G

G/Bl

Bl/G
R/W

Bl/B

W/G

B/Bl

Bl/R

Bl/B

Bl/R
B/W
B/W

W/R

B/W

W/B
B/W

R/W

Bl/Y

Bl/Y

W/R

B/W
P/W
O/G

O/G
O/R

G/B

B/G
Y/B

Y/R

Y/G

B/R
R/B
B/Y

Y/B

Y/R

P/B
Dg
Br
Bl

G
R

R
P

Y
B/Lg

Br/B
Bl/B

R/W

B/W

B/W

B/Lg
P/W
O/G

O/R

B/G

O/R
G/Y

R/B

B/R
O/G
R/B

B/Lg
Lg

W/Bl

B/W
Br

W/B
O/W

B/Br
O/W

R/B

O/G
W/B

Y/R
Y/W

O/W

W/G
O/G

W/B
O

B/O
B

G/Y
O/B
Y

Y/G
Lbl
Lg

B
B
POSITION LIGHT(R)
LICENSE LIGHT
Br Br
B/W B/W Br B

E
B/W B
Lg Lg REAR TURN SIGNAL LIGHT (R)
B/W B/W

L
Lg B
FRONT TURN SIGNAL LIGHT (R) B/W B/W
Y
B/W BRAKE LIGHT/TAILLIGHT

P
W Lg Lg
HEADLIGHT (R) Y Y Br Gr
B/W B/W B/W B/W
HEADLIGHT (L) W W W/B W/B
Y B B

M
B/W Br Br
W B B
B/W B/W
FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

A
B B
B/W B/W

Br Br

S
B/W B/W
POSITION LIGHT (L)

B/W
W/Bl
B/W

Y/Bl
B/W
Y/W
O/G

B/Y

B/Br

Gr/W
Lbl

B/Br

B/Br
Gr/B

B/Br
B/Br

W/Bl

B/Br

G/Bl
O/Bl
Lg

B/Bl

B/W

Bl/B

B/W

B/W
B/W
O/Bl

G/B

P/W

B/W
O/B
B/W

P/B

Y/Bl

R/W

P/W
O/Y

O/W
R/B
B/R

B/R
B/R
O/G

O/R
Y/R

Y/G
B/R
B/R
B/Y
B/R

O/Y

Lbl
B

Dg
Br
Bl
R
Y

Bl

B
B
B
B
B
Br
R

G
W

G
P

B
B
B
B
B
B
R
O
Y

B/W
HORN

B/W
B/W
B/R
B/R
B/W

Bl
G

Y
Y
Y

B
B
B
G
4 5 6
B/R

Bl
Bl
B/W

R
B
O/G

B/W
B/Y
B/Y

Y
Bl
Lbl

B/R
Lg

B
B
O
B

B
IAP IAP 1
Gr/W
Gr/B
R/B
B/R
Y/R

B/R
SENSOR SENSOR TP
STP ECT 1 2 3 SENSOR
ON #1 #2 IAT
SENSOR SENSOR SPEEDOMETER REGULATOR/ 1: MAIN 30 A
OFF SENSOR GENERATOR RECTIFIER BATTERY
GEAR SENSOR STARTER
L HI FREE FAN MOTOR POSITION PAIR RELAY
PUSH PUSH PUSH LO FAN FUSE BOX SORENOID
SWITCH SWITCH
Gr/W
Gr/B
R/B
B/R

Y/R

Y/R

HORN R
PASSING DIMMER CLUTCH MOTOR 1. HEAD HI 15 A VALVE FREE
STARTER
2. HEAD LO 15 A PUSH
BUTTON TURN SIGNAL LIGHT SWITCH LEVER MOTOR
SWITCH 3. FUEL 10 A
SWITCH POSITION 4. IGNITION 15 A SIDE-STAND
SWITCH 5. SIGNAL 10 A SWITCH
6. FAN 15 A
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2 #1
INJECTOR
SV1000SK5 (For E-03, 24, 28, 33)

R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R)

L R OIL
L : TURN SIGNAL INDICATOR LIGHT (L) HAZARD ENGINESTOP STARTER FRONT BRAKE PRESSURE
B : HI-BEAM INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH SWITCH
N : NEUTRAL INDICATOR LIGHT N SPEEDOMETER B OFF OFF OFF
F : FUEL LEVEL INDICATOR LIGHT IGNITION SWITCH ON RUN PUSH ON
O F OFF
ECM
O : OIL, TEMP., FI INDICATOR LIGHT ON FUEL
ON REAR BRAKE TO
RESISTOR OFF PUMP
LOCK
SWITCH FUEL PUMP SENSOR
P RELAY
ON
M

O/W

B/Bl
Y/W
O/B

O/R
Y/G

B/R
Lbl
Lg
IGNITION IGNITION OFF

B
O/Y
Br
O
R
COIL #1 COIL #2

B/Lg
B/W

R/B
Y/R
W

W/B
R
B

Gr/W
Br/W

Br/W
B/Br
W/Bl

Bl/W

Bl/W
Gr/B

Gr/R
B/Br

Gr/R
Br/B

B/Br
O/W

Bl/G

G/Bl

Bl/G
R/W

Bl/B

O/W

B/Bl

Bl/R

Bl/B

Bl/R

O/W
B/W
B/W

W/R

B/W

B/W

R/W

Bl/Y

Bl/Y

W/R

B/W
P/W
O/R

G/B

B/G
Y/B

Y/R

Y/G

B/R
R/B
B/Y

Y/B

Y/R

P/B
Dg
Br
Bl

G
R

R
P

Y
B/Lg

Br/B
Bl/B

R/W

B/W

B/W

B/Lg
P/W
O/G

O/R

B/G

O/R
G/Y

R/B

B/R
O/G
R/B

B/Lg
Lg

W/Bl

B/W
Br

W/B
O/W

O/W

R/B

O/G
W/B

Y/R
Y/W
O/G
O

B/O
B

G/Y
O/B
Y

Y/G
Lbl
Lg

B
B
POSITION LIGHT(R)
LICENSE LIGHT
Br Br
Br B

E
B/W B/W
B/W B
Lg Lg REAR TURN SIGNAL LIGHT (R)
B/W B/W
Lg B

L
FRONT TURN SIGNAL LIGHT (R) B/W B/W
Y
B/W BRAKE LIGHT/TAILLIGHT

P
W Lg Lg
Y Y Br Gr
HEADLIGHT (R)
B/W B/W B/W B/W
HEADLIGHT (L) W W W/B W/B
Y B B

M
B/W Br Br
W B B
B/W B/W

FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

A
B B
B/W B/W

S
Br Br
B/W B/W
POSITION LIGHT (L)

B/W
W/Bl
B/W

Y/Bl
B/W
Y/W
O/G

B/Y

B/Br

Gr/W
Lbl

B/Br

B/Br
Gr/B

B/Br
B/Br

W/Bl

B/Br

G/Bl

B/W
B/W
O/Bl
Lg

B/Bl

B/W

Bl/B

B/W
O/Bl

G/B

P/W

B/W
O/B
B/W

B/R
B/R
P/B

Y/Bl

R/W

P/W
O/Y

O/W
R/B
B/R

O/G

O/R
Y/R

B/R

O/Y

Lbl
B

Y/G
B/R
B/R
B/Y
Dg
Br
Bl
R
Y

Bl

Br
R

B
B
B
G
W

G
P

B
B
B
R
O
Y

B/W
HORN

B/W
B/W
B/R
B/R
B/W

Bl
G

B
B
B
Y
Y
Y
G
4 5 6
B/R

Bl
Bl
B/W

R
B
O/G

B/W
B/Y
B/Y

Y
Bl
Lbl

B/R
Lg

B
B
O
B

B
IAP IAP 1
Gr/W
Gr/B
R/B
B/R
Y/R

B/R SENSOR SENSOR TP

STP 1 2 3
ON
#1 #2 ECT IAT SENSOR
SENSOR REGULATOR/ 1: MAIN 30 A
OFF SENSOR SENSOR SPEEDOMETER GENERATOR RECTIFIER BATTERY
GEAR STARTER
POSITION SENSOR
L HI FREE FAN MOTOR FUSE BOX RELAY
PUSH PUSH PUSH LO SWITCH FAN SWITCH PAIR
Gr/W
Gr/B
R/B
B/R

Y/R

Y/R

HORN R
PASSING DIMMER CLUTCH MOTOR 1. HEAD HI 15 A SORENOID FREE
STARTER
2. HEAD LO 15 A PUSH
BUTTON TURN SIGNAL LIGHT SWITCH LEVER VALVE MOTOR
SWITCH 3. FUEL 10 A
SWITCH POSITION 4. IGNITION 15 A SIDE-STAND
SWITCH 5. SIGNAL 10 A SWITCH
6. FAN 15 A
HANDLEBAR SWITCH (L)
ACTUATOR
MOTOR
#2 #1
INJECTOR
Printed in Japan
K5