2005-07 Suzuki SV1000 Installation & Operation Manual

2005-07 Suzuki SV1000 Installation & Operation Manual

Thank you for purchasing a genuine Two Brothers Racing JUICE BOX™. This product represents a radical step forward in tuning fuel-injected motorcycles and ATVs for optimal performance using “load-based” technology. We at Two Brothers Racing hope that you will find this development as exciting and useful as we do. And remember: Proper Fuel = Maximum Power!

1. Make sure the vehicle is completely cool before starting the installation. Also, make sure the vehicle is secure and will not roll around.
2. Remove side panel screws, side panels.
3. Remove seat mount hardware, seat.
4. Remove front tank mount hardware, lift and support tank.
5. Locate JUICE BOX™ in the tail section.
6. Route the harness down the RH frame. connect ground to the negative post of the battery.
7. Route harness over rear cylinder head and down the left side of the throttle body.
8. Locate the throttle body harness connector, it’s between the LH frame and airbox. Reach in through the LH frame opening, find and disconnect. Pull the JUICE BOX™ harness connector out through the frame opening.
9. Connect the JUICE BOX™ harness to the throttle body harness. Connect the JUICE BOX™ harness to the main harness. Place a screwdriver on the back of the connector (Fig 7) to hold it. Reach in through the frame opening and connect the JUICE BOX™
10. Start the bike. The green LED should scroll left to right and back for about 3-5 seconds and then go to 1-2 steady or slowly flashing green LED’s. If the number 1 green LED and number 8 red LED’s continue flashing after startup or idling, an injector wiring error is indicated. Re-check the wires from the JUICE BOX™ and make sure they are connected to the proper wire of your bike’s stock harness. MAKE SURE you have the correct wires selected in the stock harness. DO NOT PROCEED UNLESS ABOVE CONDITIONS ARE MET.

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Suzuki SV1000 Specifications

Suzuki SV1000 Specifications

A vibrant, litre-class V-Twin delivering thumping drive out of corners along with a spine-tingling exhaust note. A compact lightweight chassis providing razor-sharp responses and a stream of dependable feedback from every twist, turn and bump in the tarmac. The SV1000, a no-nonsense naked roadster with a smartly packaged combination of advanced features - innovative SDTV (Suzuki Dual Throttle Valve) digital fuel injection, aluminium-alloy truss frame, comfortable riding position, and more - is ready to serve up what every true biker craves: a stimulating dialogue between road and rider.

Cruising through town, taking on a fast country switchback - whatever the road, the SV1000 is in its element, beckoning you to try them all.

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Suzuki TTL Manual - Throttle Actuator Installation Instructions pdf

Suzuki TTL Manual - Throttle Actuator Installation Instructions pdf

This application can be a difficult throttle installation, and requires the use of a Torque Wrench in the installation. Since this engine is so tightly packaged, you may wish to have your Suzuki/OMC dealer install this for you. Read through the instructions completely before proceeding. If you have any questions, please don’t hesitate to call our technical service advisors. 1-800-588-7655.

Step One:
Disconnect motor from battery and or disconnect safety lanyard, to prevent motor from starting during throttle actuator installation

Step Two:
Remove Cover (cowling) from motor.

Step Three:
Remove the right side cover as described in the Service Manual.

Step Four:
Remove the carburetor as described in the Service Manual. Leave the fuel hose attached, as shown in figure 5.

Step Five:
Remove the outer throttle lever parts. See figures 5 and 6. Note the order and orientation of these parts as they are removed. See Figure 7

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WXT510 WMT50 Wiring Diagram pdf

WXT510 WMT50 Wiring Diagram pdf

To avoid exceeding the maximum ratings in any condition, the voltages must be checked with no load at the power supply output.

Electrical Connections
Wiring Using the Screw Terminals
WARNING Make sure that you connect only de-energized wires.

1. Loosen the three long screws at the bottom of the WXT510/WMT50.
2. Pull out the WXT510/WMT50 bottom part.
3. Insert the power supply wires and signal wires through the cable gland(s) in the bottom part.
4. Connect the wires according to Table1.
5. Replace the bottom part and tighten the three screws.

Wiring Using the 8-pin M12 Connector
External Wiring
If the WXT510/WMT50 is provided with an optional 8-pin M12 connector, the connector is located on the bottom of the transmitter. The pins of the 8-pin M12 connector as seen from outside the transmitter are illustrated in the following figure.

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