Suzuki Intruder VS1400 Manuals

Manuals and User Guides for Suzuki Intruder VS1400. We have 3 Suzuki Intruder VS1400 manuals available for free PDF download: Service Manual, Owner's Manual

Suzuki Intruder VS1400 Service Manual (292 pages)

Brand: Suzuki | Category: Motorcycle | Size: 19 MB

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

Suzuki Intruder VS1400 Owner's Manual (163 pages)

Brand: Suzuki | Category: Motorcycle | Size: 4 MB

Table of Contents

7
- The Sport of Motorcycling
  9
- Fuel, Engine Oil and Coolant Recommendation
  20
Controls, Equipment and Adjust- Ments

25
- Controls, Equipment and Adjustments
  25
- Location of Parts
  26
- Key
  29
- Ignition Switch
  30
- Steering Lock
  31
- Instrument Panel
  32
- Left Handlebar
  34
- Right Handlebar
  35
- Fuel Tank Cap
  38
- Fuel Valve
  39
- Choke Lever
  41
- Gearshift Lever
  42
- Helmet Holder
  43
- Rear Brake Pedal
  43
- Side Stand
  44
- Rear Suspension
  46
- Break-In and Inspection before Riding
  47
Riding Tips

53
- Starting the Engine
  54
- Starting off and Shifting
  55
- Using the Transmission
  57
- Riding on Hills
  58
- Stopping and Parking
  59
- Carrying a Passenger
  61
- Accessory Use and Motorcycle Loading
  63
Inspection and Maintenance

69
- Maintenance Schedule
  70
- Notice
  70
- Tools
  75
- General Lubrication
  76
- Battery
  77
- Air Cleaner
  80
- Spark Plug
  90
- Engine Oil
  92
- Carburetor
  99
- Clutch
  102
- Final Gear Oil
  104
- Brakes
  106
- Tires
  112
- Spoke Nipple Tightness
  115
- Side Stand/Ignition Inter-Lock System
  116
- Front Wheel Removal
  118
- Rear Wheel Removal
  120
- Light Bulb Replacement
  123
- Fuses/Output Terminal
  128
- Troubleshooting
  131
Storage Procedure and Appear- Ance Care

137
- Storage Procedure and Appearance Care
  137
- Motorcycle
  138
- Fuel
  139
- Battery
  140
- Engine
  140
- External
  141
- Tires
  141
- Maintenance During Storage
  142
- Procedure for Returning to Service
  142
- Corrosion Prevention
  143
- Motorcycle Cleaning
  145
- Inspection after Cleaning
  147
- Consumer Information
  149
- Emission Control Warranty
  150
- Tampering with Noise Control System Prohibited
  151
- Serial Number Location
  152
- Reporting Safety Defects
  153
- Location of Labels
  154
- Specifications
  156
- Index
  160

Suzuki Intruder VS1400 Owner's Manual (68 pages)

Brand: Suzuki | Category: Motorcycle | Size: 22 MB

Break-In (Running-In) Information
2
Table of Contents
3
Consumer Information
4
Accessory Information and Precautions Safety Tips
5
Safe Riding Recommendation for Motorcycle Riders
6
Serial Number Location
7
Table of Contents
8
Controls
8
Location of Parts
9
- Handlebar View
  9
- Vehicle Left Side View
  9
- Vehicle Right Side View
  10
Key
10
Ignition Switch
10
Steering Lock
11
Instrument Panel
11
Left Handlebar
12
Right Handlebar
13
- Fuel Tank Cap
  14
- Fuel Valve
  15
Fuel Valve
16
Off Position
16
Choke Handle
16
- Gearshift Level
  17
- Rear Brake Pedal
  17
Helmet Holder
17
- Side Stand
  18
- Rear Suspension Spring Adjustment
  19
Suspension Adjustment
19
- Fuel and Oil Recommendation
  20
- Fuel/Oil Recommendation
  21
- Engine Oil
  21
- Final Gear Oil
  22
- SAE Engine Oil Viscosity
  22
- Jaso T903
  22
- Energy Conserving
  22
- Break-In (Running-In) and Inspection before Riding
  23
- Avoid Constant Low Speed
  24
- Vary the Engine Speed
  24
- Breaking in the New Tires
  24
- Maximum Engine Speed Recommendation
  24
- Inspection before Riding
  25
- Allow Engine to Circulate before Riding
  25
- Observe Your First and most Critical Service
  25
- Riding Tips
  26
- Starting the Engine
  27
- Starting off
  27
- Using the Transmission
  28
- Riding on Hills
  29
- Stopping and Parking
  29
- Inspection and Maintenance
  30
- Maintenance Schedule
  31
- Maintenance Chart
  32
- Lubrication Points
  33
- Tool
  33
- Battery
  34
- Air Cleaner
  36
- Spark Plugs
  40
- Plug Replacement Guide
  40
- Engine Oil Info
  41
- Engine Oil and Filter Change
  41
- Engine Level Check
  41
- Idle Speed Adjustment
  44
- Carburetor
  44
- Clutch
  45
- Throttle Cable Adjustment
  45
- Final Gear Oil Change
  46
- Brakes
  47
- Brake Fluid
  47
- Brake Pads
  48
- Rear Brake Pedal Adjustment
  49
- Rear Brake Light Switch
  49
- Tires
  50
- Tire Pressure and Loading
  50
- Spoke Nipple Tightness
  50
- Tire Conditon and Type
  51
- Cold Tire Inflation Pressure
  51
- Side Standing/Ignition Interlock Switch
  52
- Front Wheel Removal
  52
- Rear Wheel Removal
  54
- Light Bulb Replacement
  55
- Headlight
  55
- Tail/Brake Light
  56
- License Plate Light
  56
- Turn Signal Light
  57
- Headlight Beam Adjustment
  57
- Output Terminal
  58
- Fuse List
  58
- Fuses/Output Terminal Fuses
  58
- Troubleshooting
  59
- Fuel Supply Check
  60
- Motorcycle Cleaning and Storage Procedure
  61
- Ignition System Check
  61
- Engine Stalling
  61
- Washing the Motorcycle
  62
- Waxing the Motorcycle
  62
- Inspection after Cleaning
  62
- Storage Procedure
  63
- Specifications
  65
- Index
  67

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Suzuki Intruder VS1400 Service Manual (292 pages)

Table of Contents

Suzuki Intruder VS1400 Owner's Manual (163 pages)

Table of Contents

Table of Contents

Controls, Equipment and Adjust- Ments

Riding Tips

Inspection and Maintenance

Storage Procedure and Appear- Ance Care

Suzuki Intruder VS1400 Owner's Manual (68 pages)

Table of Contents

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