Table Of Contents - Suzuki Intruder VS1400 Service Manual

Table of Contents

View Of Suzuki Vs1400Glf3
Group Index4
General Information5
Serial Number Locations6
Furl And Oil Recommendations6
Final Gear Oil/Front Fork Oil7
Brake And Clutch Fluid7
Breaking-In Procedures7
Cylinder Identification7
Special Materials8
Precautions And General Instructions10
Use Of Genuine Suzuki Parts10
Specifications11
Periodic Maintenance And Tune-Up Procedures12
Periodic Maintenance Schedule13
Battery Maintenance14
Air Cleaner Maintenance15
Spark Plug Maintenance16
Engine Oil Change And Oil Filter Maintenance18
Carburetor Maintenance19
Necessary Amount Of Engine Oil19
Automatic De-Compression Cable Maintenance20
Fuel Line Maintenance21
Clutch Maintenance21
Clutch Fluid Level21
Bleeding Air From The Clutch Fluid Circuit21
Final Gear Oil22
Brake Maintenance23
Brake Fluid Level23
Bleeding Air From The Brake Fluid Circuit24
Tire Tread Condition25
Tire Pressure26
Steering Maintenance26
Front Fork Maintenance26
Chassis Bolts And Nuts27
Periodic Maintenance And Tune-Up Procedures - Illustrations28
Lubrication Points29
Engine30
Compression Check31
Engine Components Removable With The Engine In Place32
Engine Removal33
Engine Reinstallation40
Engine Disassembly42
Bearings And Oil Seals (Except For Crankshaft)56
Engine Components Inspection And Servicing57
Cylinder Head Disassembly And Servicing57
Cylinder Head Cover Distortion60
Rocker Arm Shaft O.d.60
Rocker Arm I.d.60
Cylinder Head Distortion60
Valve Face Wear/Stem Runout61
Valve Head Radial Runout61
Valve Guide - Valve Stem Clearance62
Valve Stem Wear62
Valve Guide Servicing62
Valve Stem Width64
Valve Seat Servicing64
Valve Stem End Condition66
Valve Springs (Refer To Service Data)66
Lash Adjuster Inspection67
Cam Chain Tensioner69
Cam Chain 20-Pitch Length69
Camshaft69
Cam Height70
Camshaft Runout70
Camshaft Journal Wear70
Cylinder Distortion71
Cylinder Bore72
Piston Diameter72
Piston-Cylinder Clearance72
Piston Ring-Groove Clearance73
Piston Ring - Free End Gap And End Gap73
Oversize Piston Rings/Oil Rings/Side Rail74
Piston Pin And Pin Bore74
Conrod Small End Bore I.d.75
Conrod Big End Thrust Clearance75
Conrod-Crank Pin Bearing Selection76
Conrod I.d. Specification77
Crank Pin O.d. Specification77
Bearing Thickness Table78
Bearing Assembly78
Crankshaft79
Crankcase-Crankshaft Bearing - Oil Clearance79
Crankshaft Thrust Clearance80
List Of Thrust Shims81
Clutch81
Clutch Dirve Plates And Driven Plates81
Clutch Spring Free Lendth82
Clutch Bearings/Cylinder82
Clutch Cylinder Reassembly83
Generator And Signal Generator83
Starter Clutch84
Transmission, Transmission Gears And Related Parts87
Gear-Shifting Fork Clearance88
Countershaft Reassembly88
Driveshaft Reassembly89
Engine Reassembly90
Camshaft Timing106
No 1 (Rear) Cylinder107
No 2 (Front) Cylinder108
Cam Shaft Timing109
Cylinder Head Bolt/Cylinder Head Cover Bolt Diagrams112
Gasket Position Diagram113
Liquid Gasket Applying Places Of Cylinder Head Cover113
Shaft Drive114
Shaft Drive Diagram115
Secondary Bevel Gears Construction - Exploded Diagram116
Secondary Drive Bevel Gear Removal And Disassembly117
Secondary Driven Bevel Gear118
Secondary Driven Bevel Gear Inspection119
Damper Spring Check119
Secondary Bevel Gears Reassembly119
Secondary Drive Bevel Gear119
Secondary Gears Shim Adjustment - Backlash121
Tooth Contact123
Final Assembly And Remounting124
Secondary Bevel Gears Reassembly Information125
Final Bevel Gears Construction126
Final Gear Case Breather Circuit127
Air And Gear Oil Flow In Final Gear Case Breather Circuit127
Breather Circuit127
Air/Oil Passage127
Final Bevel Gears Removal And Disassembly128
Final Gear Case128
Propeller Shaft128
Final Drive Bevel Gear129
Driven Bevel Gear130
Final Bevel Gears Inspection/Reassembly133
Drive Bevel Gear134
Final Gear Case And Bearing Case135
Final Gear Shim Adjustment138
Final Gear Bearing Case Shim Clearance138
Final Bevel Gears Assembly And Remounting141
Final Bevel Gears Reassembly Information144
Fuel And Lubrication System145
Fuel System Description And Diagram146
Fuel System When Starting Engine/After Starting Engine147
Fuel Cock147
Main Cock147
Sub Cock148
Fuel Pump148
Fuel Pump Relay149
Carburetor Construction150
No 1 (Rear) Carburetor151
Carburetor Specifications152
Diaphragm And Piston Operation153
Slow System154
Transient Enrichment System154
Main System155
Starter System156
Float System156
Carburetor Disassembly157
Front Carburetor Disassembly158
Rear Carburetor Disassembly159
Carburetor Inspection164
Carburetor Reassembly165
Balancing Carburetors166
Lubricatin System And Cooling System169
Oil Pressure169
Lubrication System Chart171
Lubrication System Diagram172
Cooling System Chart173
Cooling System Diagram174
Electrical System175
Charging System Description176
Function Of Regulator176
Charging System Inspection178
Charging Output Check178
Ac Generator No-Load Performance178
Ac Generator Continuity Check179
Regulator/Rectifier179
Ignition System Description180
Ignition System Inspection181
Ignition Coils/Pick Up Coil Check181
Ignitor Unit (Transistor Unit) Check182
Side Stand And Neutral Relay Check184
Diode Check184
Automatic De-Compression Control And Starter System Description/Operation185
Starter Motor Removal/Disassembly/Inspection186
Commutator Check186
Bearings Check186
Armature Coil Check187
Starter Motor Reassembly187
Housing End (Inside)/Screw188
Starter Relay Inspection188
Decompression Solenoid Control Unit189
Timer I/Ii Inspection189
De-Comp. Solenoid Inspection/Removal191
Speedometer And Instrument Panel Removal And Disassembly192
Speedometer And Instrument Panel Inspection194
Lamps Diagrams196
Switches197
Oil Pressure Switch198
Battery Removal198
Battery Remounting/Specifications/Initial Charging199
Battery Servicing201
Recharging Operation201
Chassis202
Front Wheel Diagram/Removal/Disassembly203
Brake Disc204
Wheel Bearings Inspection204
Axle Shaft/Wheel Rim/Tire Inspection205
Front Wheel Reassembly206
Front Brake208
Brake Pad Replacement208
Caliper Removal And Disassembly208
Caliper And Disc Inspection210
Caliper Reassembly211
Master Cylinder Removal And Disassembly211
Master Cylinder Inspection213
Master Cylinder Reassembly214
Front Fork Removal214
Front Fork Disassembly215
Front Fork Inspection218
Inner Tube And Outer Tube/Damper Rod Ring Inspection218
Front Fork Reassembly218
Oil Lock Piece Installation219
Damper Rod Bolt219
Outer Tube Metal, Oil Seal And Dust Seal219
Fork Oil219
Fork Spring220
Inner Tube220
Handlebar And Steering Stem Diagram/Disassembly221
Handlebar And Steering Stem Inspection/Reassembly224
Stem Unit225
Handlebar Holder225
Handlebars226
Rear Brake227
Brake Pad Repacement (Rear Brake)228
Caliper Removal And Disassembly (Rear Brake)228
Cylinder And Piston Inspection230
Rubber Part Inspection230
Caliper Reassembly (Rear Brake)231
Master Cylinder Removal And Disassembly (Rear Brake)233
Cylinder Inspection234
Piston, Cup Set And Rubber Parts Inspection235
Master Cylinder Reassembly And Remounting235
Rear Wheel Diagram/Removal/Disassembly236
Rear Wheel Disassembly237
Rear Wheel Inspection/Reassembly238
Rear Suspension And Swingarm Diagram/Removal240
Bearing/Dust Seal/Rear Shock Absorber Inspection242
Swingarm And Rear Shock Absorber Reassembly243
Clutch Master Cylinder Diagram244
Clutch Master Cylinder Removal And Disassembly245
Master Cylinder Inspection (Rear Wheel)246
Master Cylinder Reassembly (Rear Wheel)247
Servicing Information248
Troubleshooting249
Engine - Troubleshooting249
Shaft Drive - Troubleshooting251
Carburetor - Troubleshooting252
Electrical - Troubleshooting253
Battery/Chassis - Troubleshooting254
Brakes - Troubleshooting255
Wiring Diagram (For West Germany)256
Wiring Diagram (For Uk And Belgium)257
Wiring Diagram (The Others)258
Harness Routing Diagram259
Starter Motor Lead Diagram260
Generator Stator Diagram261
Fuel Hose Routing Diagram262
Oil Hose Routing Diagram263
Front Brake Hose Routing Diagram264
Bear Brake Hose Routing Diagram265
Cable Routing Diagram266
Location Of Clutch/Front Brake Master Cylinder268
Special Tools269
Engine - Tightening Torque274
Secondary And Final/Chassis - Tightening Torque276
Tightening Torque Chart For Other Bolts And Nuts277
Valve + Guide Service Data278
Camshaft + Cylinder Head Service Data279
Cylinder + Piston + Piston Ring Service Data279
Conrod + Crankshaft Service Data280
Oil Pump/Clutch/Transmission Service Data281
Shaft Drive/Carburetor Service Data282
Electrical Service Data283
Wattage Service Data284
Brake + Wheel Service Data284
Suspension/Ture Pressure/Fuel + Oil Service Data285
Clutch Set Bolts, Spacers And Springs287
Modification Of Pull Back Handlebars288
Modification Of The Fuel Hoses And Their Routing289
Fuel Hose Routing290