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Suzuki Intruder VS1400 Service Manual

Also See for Intruder VS1400

Owner's manual - 67 pages

291

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Table of Contents

3
View of Suzuki VS1400GLF
4
Group Index
5
General Information
6
Serial Number Locations
6
Furl and Oil Recommendations
7
Final Gear Oil/Front Fork Oil
7
Brake and Clutch Fluid
7
Breaking-in Procedures
7
Cylinder Identification
8
Special Materials
10
Precautions and General Instructions
10
Use of Genuine Suzuki Parts
11
Specifications
12
Periodic Maintenance and Tune-up Procedures
13
Periodic Maintenance Schedule
14
Battery Maintenance
15
Air Cleaner Maintenance
16
Spark Plug Maintenance
18
Engine Oil Change and Oil Filter Maintenance
19
Carburetor Maintenance
19
Necessary Amount of Engine Oil
20
Automatic De-compression Cable Maintenance
21
Fuel Line Maintenance
21
Clutch Maintenance
21
Clutch Fluid Level
21
Bleeding Air From the Clutch Fluid Circuit
22
Final Gear Oil
23
Brake Maintenance
23
Brake Fluid Level
24
Bleeding Air From the Brake Fluid Circuit
25
Tire Tread Condition
26
Tire Pressure
26
Steering Maintenance
26
Front Fork Maintenance
27
Chassis Bolts and Nuts
28
Periodic Maintenance and Tune-up Procedures - Illustrations
29
Lubrication Points
30
Engine
31
Compression Check
32
Engine Components Removable With the Engine in Place
33
Engine Removal
40
Engine Reinstallation
42
Engine Disassembly
56
Bearings and Oil Seals (Except for Crankshaft)
57
Engine Components Inspection and Servicing
57
Cylinder Head Disassembly and Servicing
60
Cylinder Head Cover Distortion
60
Rocker Arm Shaft O.D.
60
Rocker Arm I.D.
60
Cylinder Head Distortion
61
Valve Face Wear/stem Runout
61
Valve Head Radial Runout
62
Valve Guide - Valve Stem Clearance
62
Valve Stem Wear
62
Valve Guide Servicing
64
Valve Stem Width
64
Valve Seat Servicing
66
Valve Stem End Condition
66
Valve Springs (Refer to Service Data)
67
Lash Adjuster Inspection
69
Cam Chain Tensioner
69
Cam Chain 20-Pitch Length
69
Camshaft
70
Cam Height
70
Camshaft Runout
70
Camshaft Journal Wear
71
Cylinder Distortion
72
Cylinder Bore
72
Piston Diameter
72
Piston-cylinder Clearance
73
Piston Ring-groove Clearance
73
Piston Ring - Free End Gap and End Gap
74
Oversize Piston Rings/oil Rings/side Rail
74
Piston Pin and Pin Bore
75
Conrod Small End Bore I.D.
75
Conrod Big End Thrust Clearance
76
Conrod-crank Pin Bearing Selection
77
Conrod I.D. Specification
77
Crank Pin O.D. Specification
78
Bearing Thickness Table
78
Bearing Assembly
79
Crankshaft
79
Crankcase-crankshaft Bearing - Oil Clearance
80
Crankshaft Thrust Clearance
81
List of Thrust Shims
81
Clutch
81
Clutch Dirve Plates and Driven Plates
82
Clutch Spring Free Lendth
82
Clutch Bearings/cylinder
83
Clutch Cylinder Reassembly
83
Generator and Signal Generator
84
Starter Clutch
87
Transmission, Transmission Gears and Related Parts
88
Gear-shifting Fork Clearance
88
Countershaft Reassembly
89
Driveshaft Reassembly
90
Engine Reassembly
106
Camshaft Timing
107
No 1 (Rear) Cylinder
108
No 2 (Front) Cylinder
109
Cam Shaft Timing
112
Cylinder Head Bolt/cylinder Head Cover Bolt Diagrams
113
Gasket Position Diagram
113
Liquid Gasket Applying Places of Cylinder Head Cover
114
Shaft Drive
115
Shaft Drive Diagram
116
Secondary Bevel Gears Construction - Exploded Diagram
117
Secondary Drive Bevel Gear Removal and Disassembly
118
Secondary Driven Bevel Gear
119
Secondary Driven Bevel Gear Inspection
119
Damper Spring Check
119
Secondary Bevel Gears Reassembly
119
Secondary Drive Bevel Gear
121
Secondary Gears Shim Adjustment - Backlash
123
Tooth Contact
124
Final Assembly and Remounting
125
Secondary Bevel Gears Reassembly Information
126
Final Bevel Gears Construction
127
Final Gear Case Breather Circuit
127
Air and Gear Oil Flow in Final Gear Case Breather Circuit
127
Breather Circuit
127
Air/oil Passage
128
Final Bevel Gears Removal and Disassembly
128
Final Gear Case
128
Propeller Shaft
129
Final Drive Bevel Gear
130
Driven Bevel Gear
133
Final Bevel Gears Inspection/reassembly
134
Drive Bevel Gear
135
Final Gear Case and Bearing Case
138
Final Gear Shim Adjustment
138
Final Gear Bearing Case Shim Clearance
141
Final Bevel Gears Assembly and Remounting
144
Final Bevel Gears Reassembly Information
145
Fuel and Lubrication System
146
Fuel System Description and Diagram
147
Fuel System When Starting Engine/after Starting Engine
147
Fuel Cock
147
Main Cock
148
Sub Cock
148
Fuel Pump
149
Fuel Pump Relay
150
Carburetor Construction
151
No 1 (Rear) Carburetor
152
Carburetor Specifications
153
Diaphragm and Piston Operation
154
Slow System
154
Transient Enrichment System
155
Main System
156
Starter System
156
Float System
157
Carburetor Disassembly
158
Front Carburetor Disassembly
159
Rear Carburetor Disassembly
164
Carburetor Inspection
165
Carburetor Reassembly
166
Balancing Carburetors
169
Lubricatin System and Cooling System
169
Oil Pressure
171
Lubrication System Chart
172
Lubrication System Diagram
173
Cooling System Chart
174
Cooling System Diagram
175
Electrical System
176
Charging System Description
176
Function of Regulator
178
Charging System Inspection
178
Charging Output Check
178
AC Generator No-load Performance
179
AC Generator Continuity Check
179
Regulator/rectifier
180
Ignition System Description
181
Ignition System Inspection
181
Ignition Coils/pick Up Coil Check
182
Ignitor Unit (Transistor Unit) Check
184
Side Stand and Neutral Relay Check
184
Diode Check
185
Automatic De-compression Control and Starter System Description/operation
186
Starter Motor Removal/disassembly/inspection
186
Commutator Check
186
Bearings Check
187
Armature Coil Check
187
Starter Motor Reassembly
188
Housing End (Inside)/screw
188
Starter Relay Inspection
189
Decompression Solenoid Control Unit
189
Timer I/II Inspection
191
De-comp. Solenoid Inspection/removal
192
Speedometer and Instrument Panel Removal and Disassembly
194
Speedometer and Instrument Panel Inspection
196
Lamps Diagrams
197
Switches
198
Oil Pressure Switch
198
Battery Removal
199
Battery Remounting/specifications/initial Charging
201
Battery Servicing
201
Recharging Operation
202
Chassis
203
Front Wheel Diagram/removal/disassembly
204
Brake Disc
204
Wheel Bearings Inspection
205
Axle Shaft/wheel Rim/tire Inspection
206
Front Wheel Reassembly
208
Front Brake
208
Brake Pad Replacement
208
Caliper Removal and Disassembly
210
Caliper and Disc Inspection
211
Caliper Reassembly
211
Master Cylinder Removal and Disassembly
213
Master Cylinder Inspection
214
Master Cylinder Reassembly
214
Front Fork Removal
215
Front Fork Disassembly
218
Front Fork Inspection
218
Inner Tube and Outer Tube/damper Rod Ring Inspection
218
Front Fork Reassembly
219
Oil Lock Piece Installation
219
Damper Rod Bolt
219
Outer Tube Metal, Oil Seal and Dust Seal
219
Fork Oil
220
Fork Spring
220
Inner Tube
221
Handlebar and Steering Stem Diagram/disassembly
224
Handlebar and Steering Stem Inspection/reassembly
225
Stem Unit
225
Handlebar Holder
226
Handlebars
227
Rear Brake
228
Brake Pad Repacement (Rear Brake)
228
Caliper Removal and Disassembly (Rear Brake)
230
Cylinder and Piston Inspection
230
Rubber Part Inspection
231
Caliper Reassembly (Rear Brake)
233
Master Cylinder Removal and Disassembly (Rear Brake)
234
Cylinder Inspection
235
Piston, Cup Set and Rubber Parts Inspection
235
Master Cylinder Reassembly and Remounting
236
Rear Wheel Diagram/removal/disassembly
237
Rear Wheel Disassembly
238
Rear Wheel Inspection/reassembly
240
Rear Suspension and Swingarm Diagram/removal
242
Bearing/dust Seal/rear Shock Absorber Inspection
243
Swingarm and Rear Shock Absorber Reassembly
244
Clutch Master Cylinder Diagram
245
Clutch Master Cylinder Removal and Disassembly
246
Master Cylinder Inspection (Rear Wheel)
247
Master Cylinder Reassembly (Rear Wheel)
248
Servicing Information
249
Troubleshooting
249
Engine - Troubleshooting
251
Shaft Drive - Troubleshooting
252
Carburetor - Troubleshooting
253
Electrical - Troubleshooting
254
Battery/Chassis - Troubleshooting
255
Brakes - Troubleshooting
256
Wiring Diagram (For West Germany)
257
Wiring Diagram (For UK and Belgium)
258
Wiring Diagram (The Others)
259
Harness Routing Diagram
260
Starter Motor Lead Diagram
261
Generator Stator Diagram
262
Fuel Hose Routing Diagram
263
Oil Hose Routing Diagram
264
Front Brake Hose Routing Diagram
265
Bear Brake Hose Routing Diagram
266
Cable Routing Diagram
268
Location of Clutch/front Brake Master Cylinder
269
Special Tools
274
Engine - Tightening Torque
276
Secondary and Final/Chassis - Tightening Torque
277
Tightening Torque Chart for Other Bolts and Nuts
278
Valve + Guide Service Data
279
Camshaft + Cylinder Head Service Data
279
Cylinder + Piston + Piston Ring Service Data
280
Conrod + Crankshaft Service Data
281
Oil Pump/Clutch/Transmission Service Data
282
Shaft Drive/Carburetor Service Data
283
Electrical Service Data
284
Wattage Service Data
284
Brake + Wheel Service Data
285
Suspension/Ture Pressure/Fuel + Oil Service Data
287
Clutch Set Bolts, Spacers and Springs
288
Modification of Pull Back Handlebars
289
Modification of the Fuel Hoses and Their Routing
290
Fuel Hose Routing

9 9 5 0 0 - 3 9 1 5 4 - 0 1 E

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Table of Contents

3
View of Suzuki VS1400GLF
4
Group Index
5
General Information
6
Serial Number Locations
6
Furl and Oil Recommendations
7
Final Gear Oil/Front Fork Oil
7
Brake and Clutch Fluid
7
Breaking-in Procedures
7
Cylinder Identification
8
Special Materials
10
Precautions and General Instructions
10
Use of Genuine Suzuki Parts
11
Specifications
12
Periodic Maintenance and Tune-up Procedures
13
Periodic Maintenance Schedule
14
Battery Maintenance
15
Air Cleaner Maintenance
16
Spark Plug Maintenance
18
Engine Oil Change and Oil Filter Maintenance
19
Carburetor Maintenance
19
Necessary Amount of Engine Oil
20
Automatic De-compression Cable Maintenance
21
Fuel Line Maintenance
21
Clutch Maintenance
21
Clutch Fluid Level
21
Bleeding Air From the Clutch Fluid Circuit
22
Final Gear Oil
23
Brake Maintenance
23
Brake Fluid Level
24
Bleeding Air From the Brake Fluid Circuit
25
Tire Tread Condition
26
Tire Pressure
26
Steering Maintenance
26
Front Fork Maintenance
27
Chassis Bolts and Nuts
28
Periodic Maintenance and Tune-up Procedures - Illustrations
29
Lubrication Points
30
Engine
31
Compression Check
32
Engine Components Removable With the Engine in Place
33
Engine Removal
40
Engine Reinstallation
42
Engine Disassembly
56
Bearings and Oil Seals (Except for Crankshaft)
57
Engine Components Inspection and Servicing
57
Cylinder Head Disassembly and Servicing
60
Cylinder Head Cover Distortion
60
Rocker Arm Shaft O.D.
60
Rocker Arm I.D.
60
Cylinder Head Distortion
61
Valve Face Wear/stem Runout
61
Valve Head Radial Runout
62
Valve Guide - Valve Stem Clearance
62
Valve Stem Wear
62
Valve Guide Servicing
64
Valve Stem Width
64
Valve Seat Servicing
66
Valve Stem End Condition
66
Valve Springs (Refer to Service Data)
67
Lash Adjuster Inspection
69
Cam Chain Tensioner
69
Cam Chain 20-Pitch Length
69
Camshaft
70
Cam Height
70
Camshaft Runout
70
Camshaft Journal Wear
71
Cylinder Distortion
72
Cylinder Bore
72
Piston Diameter
72
Piston-cylinder Clearance
73
Piston Ring-groove Clearance
73
Piston Ring - Free End Gap and End Gap
74
Oversize Piston Rings/oil Rings/side Rail
74
Piston Pin and Pin Bore
75
Conrod Small End Bore I.D.
75
Conrod Big End Thrust Clearance
76
Conrod-crank Pin Bearing Selection
77
Conrod I.D. Specification
77
Crank Pin O.D. Specification
78
Bearing Thickness Table
78
Bearing Assembly
79
Crankshaft
79
Crankcase-crankshaft Bearing - Oil Clearance
80
Crankshaft Thrust Clearance
81
List of Thrust Shims
81
Clutch
81
Clutch Dirve Plates and Driven Plates
82
Clutch Spring Free Lendth
82
Clutch Bearings/cylinder
83
Clutch Cylinder Reassembly
83
Generator and Signal Generator
84
Starter Clutch
87
Transmission, Transmission Gears and Related Parts
88
Gear-shifting Fork Clearance
88
Countershaft Reassembly
89
Driveshaft Reassembly
90
Engine Reassembly
106
Camshaft Timing
107
No 1 (Rear) Cylinder
108
No 2 (Front) Cylinder
109
Cam Shaft Timing
112
Cylinder Head Bolt/cylinder Head Cover Bolt Diagrams
113
Gasket Position Diagram
113
Liquid Gasket Applying Places of Cylinder Head Cover
114
Shaft Drive
115
Shaft Drive Diagram
116
Secondary Bevel Gears Construction - Exploded Diagram
117
Secondary Drive Bevel Gear Removal and Disassembly
118
Secondary Driven Bevel Gear
119
Secondary Driven Bevel Gear Inspection
119
Damper Spring Check
119
Secondary Bevel Gears Reassembly
119
Secondary Drive Bevel Gear
121
Secondary Gears Shim Adjustment - Backlash
123
Tooth Contact
124
Final Assembly and Remounting
125
Secondary Bevel Gears Reassembly Information
126
Final Bevel Gears Construction
127
Final Gear Case Breather Circuit
127
Air and Gear Oil Flow in Final Gear Case Breather Circuit
127
Breather Circuit
127
Air/oil Passage
128
Final Bevel Gears Removal and Disassembly
128
Final Gear Case
128
Propeller Shaft
129
Final Drive Bevel Gear
130
Driven Bevel Gear
133
Final Bevel Gears Inspection/reassembly
134
Drive Bevel Gear
135
Final Gear Case and Bearing Case
138
Final Gear Shim Adjustment
138
Final Gear Bearing Case Shim Clearance
141
Final Bevel Gears Assembly and Remounting
144
Final Bevel Gears Reassembly Information
145
Fuel and Lubrication System
146
Fuel System Description and Diagram
147
Fuel System When Starting Engine/after Starting Engine
147
Fuel Cock
147
Main Cock
148
Sub Cock
148
Fuel Pump
149
Fuel Pump Relay
150
Carburetor Construction
151
No 1 (Rear) Carburetor
152
Carburetor Specifications
153
Diaphragm and Piston Operation
154
Slow System
154
Transient Enrichment System
155
Main System
156
Starter System
156
Float System
157
Carburetor Disassembly
158
Front Carburetor Disassembly
159
Rear Carburetor Disassembly
164
Carburetor Inspection
165
Carburetor Reassembly
166
Balancing Carburetors
169
Lubricatin System and Cooling System
169
Oil Pressure
171
Lubrication System Chart
172
Lubrication System Diagram
173
Cooling System Chart
174
Cooling System Diagram
175
Electrical System
176
Charging System Description
176
Function of Regulator
178
Charging System Inspection
178
Charging Output Check
178
AC Generator No-load Performance
179
AC Generator Continuity Check
179
Regulator/rectifier
180
Ignition System Description
181
Ignition System Inspection
181
Ignition Coils/pick Up Coil Check
182
Ignitor Unit (Transistor Unit) Check
184
Side Stand and Neutral Relay Check
184
Diode Check
185
Automatic De-compression Control and Starter System Description/operation
186
Starter Motor Removal/disassembly/inspection
186
Commutator Check
186
Bearings Check
187
Armature Coil Check
187
Starter Motor Reassembly
188
Housing End (Inside)/screw
188
Starter Relay Inspection
189
Decompression Solenoid Control Unit
189
Timer I/II Inspection
191
De-comp. Solenoid Inspection/removal
192
Speedometer and Instrument Panel Removal and Disassembly
194
Speedometer and Instrument Panel Inspection
196
Lamps Diagrams
197
Switches
198
Oil Pressure Switch
198
Battery Removal
199
Battery Remounting/specifications/initial Charging
201
Battery Servicing
201
Recharging Operation
202
Chassis
203
Front Wheel Diagram/removal/disassembly
204
Brake Disc
204
Wheel Bearings Inspection
205
Axle Shaft/wheel Rim/tire Inspection
206
Front Wheel Reassembly
208
Front Brake
208
Brake Pad Replacement
208
Caliper Removal and Disassembly
210
Caliper and Disc Inspection
211
Caliper Reassembly
211
Master Cylinder Removal and Disassembly
213
Master Cylinder Inspection
214
Master Cylinder Reassembly
214
Front Fork Removal
215
Front Fork Disassembly
218
Front Fork Inspection
218
Inner Tube and Outer Tube/damper Rod Ring Inspection
218
Front Fork Reassembly
219
Oil Lock Piece Installation
219
Damper Rod Bolt
219
Outer Tube Metal, Oil Seal and Dust Seal
219
Fork Oil
220
Fork Spring
220
Inner Tube
221
Handlebar and Steering Stem Diagram/disassembly
224
Handlebar and Steering Stem Inspection/reassembly
225
Stem Unit
225
Handlebar Holder
226
Handlebars
227
Rear Brake
228
Brake Pad Repacement (Rear Brake)
228
Caliper Removal and Disassembly (Rear Brake)
230
Cylinder and Piston Inspection
230
Rubber Part Inspection
231
Caliper Reassembly (Rear Brake)
233
Master Cylinder Removal and Disassembly (Rear Brake)
234
Cylinder Inspection
235
Piston, Cup Set and Rubber Parts Inspection
235
Master Cylinder Reassembly and Remounting
236
Rear Wheel Diagram/removal/disassembly
237
Rear Wheel Disassembly
238
Rear Wheel Inspection/reassembly
240
Rear Suspension and Swingarm Diagram/removal
242
Bearing/dust Seal/rear Shock Absorber Inspection
243
Swingarm and Rear Shock Absorber Reassembly
244
Clutch Master Cylinder Diagram
245
Clutch Master Cylinder Removal and Disassembly
246
Master Cylinder Inspection (Rear Wheel)
247
Master Cylinder Reassembly (Rear Wheel)
248
Servicing Information
249
Troubleshooting
249
Engine - Troubleshooting
251
Shaft Drive - Troubleshooting
252
Carburetor - Troubleshooting
253
Electrical - Troubleshooting
254
Battery/Chassis - Troubleshooting
255
Brakes - Troubleshooting
256
Wiring Diagram (For West Germany)
257
Wiring Diagram (For UK and Belgium)
258
Wiring Diagram (The Others)
259
Harness Routing Diagram
260
Starter Motor Lead Diagram
261
Generator Stator Diagram
262
Fuel Hose Routing Diagram
263
Oil Hose Routing Diagram
264
Front Brake Hose Routing Diagram
265
Bear Brake Hose Routing Diagram
266
Cable Routing Diagram
268
Location of Clutch/front Brake Master Cylinder
269
Special Tools
274
Engine - Tightening Torque
276
Secondary and Final/Chassis - Tightening Torque
277
Tightening Torque Chart for Other Bolts and Nuts
278
Valve + Guide Service Data
279
Camshaft + Cylinder Head Service Data
279
Cylinder + Piston + Piston Ring Service Data
280
Conrod + Crankshaft Service Data
281
Oil Pump/Clutch/Transmission Service Data
282
Shaft Drive/Carburetor Service Data
283
Electrical Service Data
284
Wattage Service Data
284
Brake + Wheel Service Data
285
Suspension/Ture Pressure/Fuel + Oil Service Data
287
Clutch Set Bolts, Spacers and Springs
288
Modification of Pull Back Handlebars
289
Modification of the Fuel Hoses and Their Routing
290
Fuel Hose Routing

Troubleshooting

Also See for Suzuki Intruder VS1400

Suzuki VS1400 Owner's Manual

Suzuki VS1400 Owner's Manual 67 pages

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Summary of Contents for Suzuki Intruder VS1400

Page 1 9 9 5 0 0 - 3 9 1 5 4 - 0 1 E...

Comments to this Manuals

Latest comments:

AMIDEN Jan 23, 2018 01:37:

MUITO BOM ESSE MANUAL DE SERVIÇO DA VS 1400. GRATO
AMIDEN Jan 23, 2018 01:37:

MUITO BOM ESSE MANUAL DE SERVIÇO DA VS 1400. GRATO
Flounder May 24, 2017 06:10:

Thanks only useful thing i found on the Internet Thanks again