Suzuki DL1000AL4 Manuale utente

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

CHolder 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

HFront 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

LBattery electrolyte

container 1

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 Aof the front side with

specified torque and then tighten the bolt Bof

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.

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