From: (Brian Faulkner)
Subject: TL update

TL1000SV Vital Updated Tuning Information

1997 new model technical update seminar

(Suzuki part # 99923-15971-001)

Note: This text was transcribed from the original Suzuki document, which did not contain a copyright notice. If Suzuki Motor Corp. wishes to claim a copyright and does not want it published here, then it will disappear...


This supplement contains additional information about TL1000SV running characteristics which was not available during 1997 New Model Update Seminar presentations. The information in this supplement is intended to familiarize your staff with the TL1000S engine performance characteristics and provide additional low RPM tuning information.

The TL1000S has a high performance V-Twin engine. This high revving engine is designed to produce optimum mid-to-high RPM power. The engine is equipped with an aggressive camshaft profile, large valves and large throttle bodies.

The TL1000S will have different running characteristics than four cylinder motorcycles, especially at lower engine speeds. When riding the TL1000S, the operator can feel the power pulses the engine produces from idle to 4000 RPM.


We recommend to put some miles, (approximately 20 miles), on a TL1000S motorcycle before performing any adjustments and delivering the motorcycle to the customer. With at least 1000 or more miles of operation the piston rings will begin to seat which will improve the effectiveness of throttle body synchronization.

Recommended Engine Speed During Break-In
Initial 500 milesBelow 5000 RPM
Up to 1000 MilesBelow 7500 RPM
Over 1000 MilesBelow 10500 RPM

Throttle Body Synchronization

Careful throttle body synchronization and throttle position sensor adjustment improve low and mid-speed throttle response and smoothness.

Follow these instructions carefully for effective throttle body synchronization, throttle position sensor adjustment, and fast idle adjustment.

TPS Adjustment & Fast Idle Adjustment

Throttle body synchronization also effects the setting of the throttle position sensor, (TPS). During synchronization the throttle valves relationship to one another changes. The TPS setting changes because the TPS is mounted on a throttle valve shaft.

To obtain the best idle and low RPM performance it is important these settings be checked and adjusted in the following sequence using the proper special tools and procedures.

1. Required Special Tools

2. Inspect Before Throttle Body Synchronization

3. Fuel Recommendations

Use only unleaded gasoline of at least 87 pump octane (R+M/2) method.

The fuel should be alcohol free whenever possible.

Blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) can be used. Blended gasoline/alcohol fuel can be used, provided the fuel does not contain more than 10% ethanol. Gasoline/alcohol with up to 5% methanol can be used if co-solvents and corrosion inhibitors are present in the fuel.

If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline.

4. Oil Recommendations

SUZUKI Performance 4 motor oil should be used. The recommended viscosity is SAE 10W/40.

Other oils may be used if they are rated SF or SG under the API,(American Petroleum Institute), service classification. Synthetic oils and friction modifier additives are not recommended, especially during the critical break in period.

If a 10W/40 oil is not available, select an alternative using the chart below. (snip of owners manual viscosity/temp. chart)

5. Oil Level

When checking oil level, hold the motorcycle upright on level ground. Do not use a service stand. Wait one minute after shutting off the engine to check the level.

Check the oil level using the inspection window on the right engine cover. The level should be in the _middle_ of the window between the upper "F" and lower "L" marks.

Add or drain oil to set the level.

CAUTION - Do not over fill the oil level or the air cleaner element may get contaminated during sustained high RPM operation.

5. Oil Level (continued)

(drawing of oil window) NOTE: When replacing the oil filter, be sure to use the proper one PN 16510-34E00 Oil Filter

This filter looks similar to the filter used on GSX-R, Katana and VS models. However, it is constructed different internally with a different oil bypass pressure valve.

Please remind your service and parts department staff of this difference so customers will receive the correct filter.

6. Pull Fairing Panels away from Frame

7. Remove Seats

8. Access Fuel Tank Prop Stand

9. Raise Fuel Tank

10. Accessing Spark Plugs

11. Spark Plugs

Standard spark plug application depends on the VIN number of the motorcycle as shown below:

Up to VIN # V2103237
From VIN # V2103237

The plugs must be resistor type, which prevents radio noise that may affect the ignition system operation.

Check for carbon deposits on the plugs. Clean the spark plugs if the deposits are not severe. It is recommended to replace the spark plugs if heavy deposits are present.

Replace the spark plugs if the electrodes are worn or burnt. Replace the spark plugs if they have broken insulators or damaged threads.

Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.

Spark Plug Gap: 0.6 - 0.7mm (0.024 - 0.028in)
Thickness Gauge: PN 09900-20803

12. Idle Adjustment

The proper idle speed is 1200 RPM.

Adjust the idle using the throttle lever stop screw. The screw is a black plastic knob mounted to the frame above the left engine cover.

Set the idle speed once the engine has warmed to operating temperature. This is 160' to 190'. The LCD on the tachometer will display the temperatures.

_Incorrect idle speed may make the engine run improperly, as throttle position sensor settings may be affected_. Turning the idle stop screw will open the throttle valve the position sensor is connected to, thus altering the sensor's adjustment.

13. FI System Self-Diagnosis

In the rare occurence that a malfunction exists, the system will detect the problem.

A "FI" symbol on the LCD tachometer display indicates a problem. A continuously lit or flashing red LED in the tachometer face accompanies the "FI" symbol.

The engine may run in "Relief Mode", with a malfunction present. However, throttle body synchronization and TPS adjustment may not be accurate if performed while the engine is in "Relief Mode".

Use the instructions in the TL1000S service manual, section 4, to troubleshoot and resolve any problem before attempting throttle body synchronization.

14. Throttle Position Sensor(TPS)

The Throttle Position Sensor, (TPS), provides the Electronic Control Unit, (ECU),critical throttle information that is used for ignition and fuel injection operation. The TPS is located on the left side of the rear throttle body.

A function of the FI system aids in TPS adjustment. An LCD on the tachometer displays FI malfunction codes and sensor adjustment bars. The bars are visible to the left of the malfunction code. Only one bar is visible at a time.

The "c00" code is visible when no malfunction is detected. If a code other than "c00" appears, follow the troubleshooting procedure in the TL1000S service manual, section 4. When the throttle position sensor is correctly adjusted, only the center bar is visible.

The Mode Selector Switch is used to display TPS alignment bars on the LCD dash.

The connector for the switch is located under the passenger seat, along the right side of the storage compartment tray. A rubber cap covers the white connector, (W/R,B/W wires).

Take the rubber cap off the connector and plug in the mode selector switch.

The screw holding the TPS to the throttle body are a tamper proof T-25 Torx style. This type of tool is needed if the TPS requires adjustment.

Use a floor mount cooling fan directed at the radiator and the engine during TPS and Throttle Body Synchronization.

When running the engine, maintain the coolant temperature between 160 to 190.

If the low fuel lamp on the dash is illuminated, lower the tank and add fuel.

To verify TPS adjustment turn the mode selector switch to "on" and use the procedure below.

15. Air Cleaner Element

A dirty or contaminated air cleaner element can keep the motorcycle from running properly. Follow the steps below to inspect and service the air cleaner and element.

16. Disconnect Intake Air Temperature Sensor

17. Disconnect Intake Air Pressure Sensor

18. Disconnect Vacuum Control Solenoid Valve

19. Remove Air Cleaner Assembly

20. Reconnect Sensors to Wiring Harness

21. Un-Cap Vacuum Nipples on Throttle Bodies

22. Balancer Adapter Hoses

23. Calibrating Vacuum Balancer Gauge

(snipping section, just deals with calibrating Suzuki's Synch gauge)

24. Throttle Body Air Screws

25. Connect the Balancer Gauge

26. Throttle Valve Synchronization

27. Throttle Lever Gap Adjustment

28. Install The Air Cleaner

29. Fast Idle Adjustment

30. Re-Check TPS Adjustment

31. Remove Mode Selector Switch

32. Verify Air Valve Operation

33. Lowering Fuel Tank

34. Secure Fairing Panels

35. Install seats

36. Test Ride Motorcycle

(Submitted by Brian Faulkner) — [Index]