Suzuki Intruder VZ1500 Manuals

Manuals and User Guides for Suzuki Intruder VZ1500. We have 2 Suzuki Intruder VZ1500 manuals available for free PDF download: Service Manual, Owner's Manual

Suzuki Intruder VZ1500 Service Manual (580 pages)

Brand: Suzuki | Category: Motorcycle | Size: 42 MB

Precautions

5
- Table of Contents
  5
- Precautions
  
  6
- Special Tools and Equipment
  
  13
  - Special Tool
    13
  - General Information
    15
    
    Cylinder Identification
    19
    
    Front Suspension
    24
    
    Lubrication Points
    31
    
    Exterior Parts
    32
    
    Service Data
    51
Section 1 Engine

63
- Precautions
  
  67
  - Precautions for Engine
    67
- General Description
  
  68
  - Injection Timing Description
    68
  - Self-Diagnosis Function
    69
- Engine General Information and Diagnosis
  
  68
- Schematic and Routing Diagram
  
  71
  - FI System Wiring Diagram
    71
  - Terminal Alignment of ECM Coupler
    72
- Component Location
  
  73
  - FI System Parts Location
    73
- Diagnostic Information and Procedures
  
  74
- Specifications
  
  163
  - Service Data
    163
- Special Tools and Equipment
  
  164
  - Special Tool
    164
- Emission Control Devices
  
  165
- Precautions
  
  165
  - Precautions for Emission Control Devices
    165
- General Description
  
  165
- Schematic and Routing Diagram
  
  170
  - PAIR System Hose Routing Diagram
    170
  - EVAP Canister Hose Routing Diagram
    171
- Repair Instructions
  
  172
  - Heated Oxygen Sensor (HO2S) Removal and Installation
    172
  - Heated Oxygen Sensor (HO2S) Inspection
    172
    
    PAIR Reed Valve Removal and Installation
    172
    
    PAIR Control Solenoid Valve Removal and Installation
    173
    
    PAIR System Inspection
    173
    
    Crankcase Breather (PCV) Hose Inspection
    174
    
    Special Tool
    174
    
    Crankcase Breather (PCV) Hose Removal and Installation
    175
    
    Evaporative Emission Control System Removal and Installation (Only for
    175
    
    Evaporative Emission Control System Inspection (for E-33 Only)
    176
- Special Tools and Equipment
  
  178
  - Recommended Service Material
    178
- Specifications
  
  178
  - Service Data
    178
  - Tightening Torque Specifications
    178
- Engine Electrical Devices
  
  179
- Precautions
  
  179
  - Precautions for Engine Electrical Device
    179
- Component Location
  
  179
  - Engine Electrical Components Location
    179
- Diagnostic Information and Procedures
  
  179
  - Engine Symptom Diagnosis
    179
- Repair Instructions
  
  179
  - ECM Removal and Installation
    179
  - CKP Sensor Inspection
    179
  - IAP Sensor Removal and Installation
    180
  - TP Sensor Inspection
    180
  - TP Sensor Removal and Installation
    180
  - TP Sensor Adjustment
    181
  - IAT Sensor Removal and Installation
    181
  - ECT Sensor Removal and Installation
    182
  - ECT Sensor Inspection
    183
  - TO Sensor Removal and Installation
    183
  - TO Sensor Inspection
    184
  - STP Sensor Inspection
    184
  - STP Sensor Adjustment
    184
  - STP Sensor Removal and Installation
    185
  - STV Actuator Inspection
    186
  - STV Actuator Removal and Installation
    186
  - ISC Valve Inspection
    186
  - ISC Valve Removal and Installation
    186
  - ISC Valve Preset and Opening Initialization
    186
  - HO2 Sensor Inspection
    187
  - HO2 Sensor Removal and Installation
    187
  - GP Switch Inspection
    187
  - GP Switch Removal and Installation
    187
- Specifications
  
  188
  - Service Data
    188
  - Tightening Torque Specifications
    188
- Special Tools and Equipment
  
  189
  - Recommended Service Material
    189
  - Special Tool
    189
- Schematic and Routing Diagram
  
  190
  - Throttle Cable Routing Diagram
    191
- Engine Mechanical
  
  190
- Diagnostic Information and Procedures
  
  192
  - Engine Mechanical Symptom Diagnosis
    192
  - Compression Pressure Check
    192
- Repair Instructions
  
  193
  - Engine Components Removable with the Engine in Place
    193
  - Air Cleaner Element Removal and Installation
    195
  - Air Cleaner Element Inspection and Cleaning
    196
  - Air Cleaner Chamber Removal and Installation
    196
  - Throttle Body Components
    198
  - Throttle Body Construction
    199
  - ISC Valve Removal and Installation
    201
  - Throttle Body Removal and Installation
    201
  - Throttle Body Disassembly and Assembly
    203
  - Throttle Body Inspection and Cleaning
    206
  - Throttle Valve Synchronization
    207
  - ISC Valve Reset
    209
  - Engine Assembly Removal
    209
  - Engine Assembly Installation
    213
  - Engine Top Side Disassembly
    216
  - Engine Top Side Assembly
    221
  - Valve Clearance Inspection and Adjustment
    230
  - Cylinder Head Cover Inspection
    230
  - Camshaft Inspection
    230
  - Automatic-Decomp. Inspection
    232
  - Cam Chain Tension Adjuster Inspection
    232
  - Cylinder Head Cover Disassembly and Assembly
    233
  - PAIR Reed Valve / PAIR Reed Valve Cover Inspection
    234
  - Cylinder Head Disassembly and Assembly
    234
  - Cylinder Head Related Parts Inspection
    236
  - Valve Guide Replacement
    239
  - Valve Seat Repair
    241
  - Cam Chain Guide Inspection
    242
  - Cylinder Inspection
    242
  - Piston Ring Removal and Installation
    242
  - Piston and Piston Ring Inspection
    244
  - Engine Bottom Side Disassembly
    245
  - Engine Bottom Side Assembly
    253
  - Cam Chain Tensioner Inspection
    262
  - Conrod Removal and Installation
    263
  - Conrod / Crankshaft Inspection
    264
  - Conrod Crank Pin Bearing Inspection and Selection
    265
  - Crankshaft Bearing Inspection and Adjustment
    266
  - Crankshaft Bearing Replacement
    267
  - Crankshaft Thrust Clearance Inspection and Adjustment
    269
- Specifications
  
  271
  - Service Data
    271
  - Tightening Torque Specifications
    273
- Special Tools and Equipment
  
  274
  - Recommended Service Material
    274
- Engine Lubrication System
  
  278
- Precautions
  
  278
  - Precautions for Engine Oil
    278
- Schematic and Routing Diagram
  
  278
  - Engine Lubrication System Chart Diagram
    278
- Diagnostic Information and Procedures
  
  279
  - Engine Lubrication Symptom Diagnosis
    279
  - Oil Pressure Check
    279
- Repair Instructions
  
  280
- Specifications
  
  287
  - Service Data
    287
  - Tightening Torque Specifications
    288
- Special Tools and Equipment
  
  288
  - Recommended Service Material
    288
  - Special Tool
    288
- Engine Cooling System
  
  289
- Precautions
  
  289
  - Precautions for Engine Cooling System
    289
  - Precautions for Engine Coolant
    289
- General Description
  
  289
  - Engine Coolant Description
    290
- Schematic and Routing Diagram
  
  290
  - Cooling Circuit Diagram
    290
  - Water Hose Routing Diagram
    291
- Repair Instructions
  
  292
  - Cooling Circuit Inspection
    292
  - Radiator Cap Inspection
    293
  - Radiator Inspection and Cleaning
    293
  - Radiator / Cooling Fan Motor Removal and Installation
    293
  - Water Hose Inspection
    294
  - Water Hose Removal and Installation
    295
  - Radiator Reservoir Tank Inspection
    295
  - Radiator Reservoir Tank Removal and Installation
    295
  - Cooling Fan Inspection
    296
  - Cooling Fan Relay Inspection
    296
  - ECT Sensor Removal and Installation
    297
  - ECT Sensor Inspection
    297
  - Thermostat Removal and Installation
    297
  - Thermostat Inspection
    298
  - Water Pump Components
    299
  - Water Pump Removal and Installation
    299
  - Water Pump Disassembly and Assembly
    301
  - Water Pump Related Parts Inspection
    303
- Diagnostic Information and Procedures
  
  292
  - Engine Cooling Symptom Diagnosis
    292
- Specifications
  
  304
  - Service Data
    304
  - Tightening Torque Specifications
    305
- Special Tools and Equipment
  
  305
  - Recommended Service Material
    305
  - Special Tool
    305
- Fuel System
  
  306
- Precautions
  
  306
  - Precautions for Fuel System
    306
- General Description
  
  307
  - Fuel System Description
    307
- Schematic and Routing Diagram
  
  308
  - Fuel Tank Breather Hose Routing Diagram
    308
- Diagnostic Information and Procedures
  
  309
  - Fuel System Diagnosis
    309
- Repair Instructions
  
  310
- Specifications
  
  321
  - Service Data
    321
  - Tightening Torque Specifications
    321
- Special Tools and Equipment
  
  322
  - Recommended Service Material
    322
  - Special Tool
    322
- Ignition System
  
  323
- Schematic and Routing Diagram
  
  323
  - Ignition System Diagram
    323
  - Ignition System Components Location
    323
- Diagnostic Information and Procedures
  
  324
  - Ignition System Symptom Diagnosis
    324
  - No Spark or Poor Spark
    325
- Repair Instructions
  
  326
- Specifications
  
  332
  - Service Data
    332
  - Tightening Torque Specifications
    332
- Special Tools and Equipment
  
  333
  - Special Tool
    333
- Diagnostic Information and Procedures
  
  334
- Schematic and Routing Diagram
  
  334
  - Starting System Diagram
    334
- Starting System
  
  334
- Component Location
  
  334
  - Starting System Components Location
    334
- Repair Instructions
  
  336
- Specifications
  
  347
  - Service Data
    347
  - Tightening Torque Specifications
    347
- Special Tools and Equipment
  
  347
  - Recommended Service Material
    347
  - Special Tool
    348
- Charging System
  
  349
- Schematic and Routing Diagram
  
  349
  - Charging System Diagram
    349
- Component Location
  
  349
  - Charging System Components Location
    349
- Diagnostic Information and Procedures
  
  350
  - Charging System Symptom Diagnosis
    350
  - Battery Runs down Quickly
    351
- Repair Instructions
  
  351
  - Battery Current Leakage Inspection
    351
  - Regulated Voltage Inspection
    352
  - Generator Inspection
    352
  - Generator Removal and Installation
    353
  - Regulator / Rectifier Inspection
    356
  - Battery Components
    357
  - Battery Charging
    357
  - Battery / Battery Holder Removal and Installation
    358
  - Battery Visual Inspection
    360
- Specifications
  
  361
  - Service Data
    361
  - Tightening Torque Specifications
    361
- Special Tools and Equipment
  
  361
  - Recommended Service Material
    361
  - Special Tool
    361
- Exhaust System
  
  362
- Precautions
  
  362
  - Precautions for Exhaust System
    362
- Repair Instructions
  
  362
- Specifications
  
  366
- Special Tools and Equipment
  
  366
  - Recommended Service Material
    366
Section 2 Suspension

367
- Precautions
  
  368
  - Precautions for Suspension
    368
- Suspension General Diagnosis
  
  369
- Diagnostic Information and Procedures
  
  369
  - Suspension and Wheel Symptom Diagnosis
    369
- Repair Instructions
  
  370
  - Front Fork Components
    370
  - Front Fork Removal and Installation
    371
  - Front Fork Disassembly and Assembly
    372
  - Front Fork Inspection
    372
  - Front Fork Parts Inspection
    377
- Front Suspension
  
  370
- Special Tools and Equipment
  
  378
  - Recommended Service Material
    378
  - Special Tool
    379
- Specifications
  
  378
  - Service Data
    378
  - Tightening Torque Specifications
    378
- Repair Instructions
  
  380
- Rear Suspension
  
  380
- Specifications
  
  391
  - Service Data
    391
  - Tightening Torque Specifications
    391
- Special Tools and Equipment
  
  391
  - Recommended Service Material
    391
  - Special Tool
    392
- Precautions
  
  393
  - Precautions for Wheel and Tire
    393
- Wheels and Tires
  
  393
- Repair Instructions
  
  394
- Specifications
  
  410
  - Service Data
    410
  - Tightening Torque Specifications
    411
- Special Tools and Equipment
  
  411
  - Recommended Service Material
    411
  - Special Tool
    412
Section 3 Driveline / Axle

413
- Precautions
  
  414
  - Precautions for Driveline / Axle
    414
- Drive Chain / Drive Train / Drive Shaft
  
  415
- Diagnostic Information and Procedures
  
  415
  - Drive Chain and Sprocket Symptom Diagnosis
    415
- Repair Instructions
  
  416
- Specifications
  
  442
  - Service Data
    442
  - Tightening Torque Specifications
    442
- Special Tools and Equipment
  
  443
  - Recommended Service Material
    443
  - Special Tool
    443
Section 4 Brake

445
- Precautions
  
  446
  - Precautions for Brake System
    446
  - Brake Fluid Information
    446
- Brake Control System and Diagnosis
  
  447
- Schematic and Routing Diagram
  
  447
  - Front Brake Hose Routing Diagram
    447
  - Rear Brake Hose Routing Diagram
    448
- Repair Instructions
  
  449
- Diagnostic Information and Procedures
  
  449
  - Brake Symptom Diagnosis
    449
- Specifications
  
  464
  - Service Data
    464
- Special Tools and Equipment
  
  465
  - Recommended Service Material
    465
  - Special Tool
    465
- Front Brakes
  
  466
- Repair Instructions
  
  466
- Specifications
  
  473
  - Service Data
    473
  - Tightening Torque Specifications
    473
- Special Tools and Equipment
  
  473
  - Recommended Service Material
    473
  - Special Tool
    474
- Rear Brakes
  
  475
- Repair Instructions
  
  475
  - Rear Brake Components
    475
  - Rear Brake Pad Inspection
    476
  - Rear Brake Pad Replacement
    476
  - Rear Brake Caliper Removal and Installation
    477
  - Rear Brake Caliper Disassembly and Assembly
    478
  - Rear Brake Caliper Parts Inspection
    480
  - Rear Brake Disc Removal and Installation
    481
  - Rear Brake Disc Inspection
    481
- Specifications
  
  482
  - Service Data
    482
  - Tightening Torque Specifications
    482
- Special Tools and Equipment
  
  483
  - Recommended Service Material
    483
  - Special Tool
    483
Section 5 Transmission / Transaxle

485
- Precautions
  
  486
  - Precautions for Transmission / Transaxle
    486
- Manual Transmission
  
  487
- Diagnostic Information and Procedures
  
  487
  - Manual Transmission Symptom Diagnosis
    487
- Repair Instructions
  
  488
- Specifications
  
  503
  - Service Data
    503
  - Tightening Torque Specifications
    504
- Special Tools and Equipment
  
  504
  - Recommended Service Material
    504
  - Special Tool
    505
- Schematic and Routing Diagram
  
  506
  - Clutch Cable Routing Diagram
    506
- Precautions
  
  506
  - Precautions for Clutch System
    506
- Diagnostic Information and Procedures
  
  506
  - Clutch System Symptom Diagnosis
    506
- Clutch
  
  506
- Repair Instructions
  
  507
  - Clutch Lever Position Switch Inspection
    507
  - Clutch Cable Removal and Installation
    507
  - Clutch Release Assembly / Push Rod
    507
  - Removal and Installation
    509
  - Clutch Release Oil Seal / Dust Seal Inspection
    509
  - Clutch Push Rod (Left) Inspection
    509
  - Clutch Components
    510
  - Clutch Removal
    511
  - Clutch Installation
    513
  - Tightening Torque
    515
  - Clutch Parts Inspection
    517
  - Primary Drive Gear Removal and Installation
    518
- Specifications
  
  519
  - Service Data
    519
  - Tightening Torque Specifications
    520
- Special Tools and Equipment
  
  520
  - Recommended Service Material
    520
  - Special Tool
    520
Section 6 Steering

523
- Precautions
  
  524
  - Precautions for Steering
    524
- Steering General Diagnosis
  
  525
- Diagnostic Information and Procedures
  
  525
  - Steering Symptom Diagnosis
    525
- Steering / Handlebar
  
  526
- Repair Instructions
  
  526
  - Handlebars Components
    526
  - Handlebars Removal and Installation
    526
  - Handlebars Inspection
    528
  - Steering Components
    529
  - Steering Removal and Installation
    529
  - Steering Related Parts Inspection
    532
  - Steering System Inspection
    532
  - Steering Stem Bearing Removal and Installation
    532
  - Steering Tension Adjustment
    533
- Specifications
  
  534
  - Tightening Torque Specifications
    534
- Special Tools and Equipment
  
  534
  - Recommended Service Material
    534
  - Special Tool
    535
Section 9 Body and Accessories

537
- Component Location
  
  539
  - Electrical Components Location
    539
- Precautions
  
  539
  - Precautions for Electrical System
    539
- Wiring Systems
  
  540
- Schematic and Routing Diagram
  
  540
  - Wiring Diagram
    540
  - Wiring Harness Routing Diagram
    544
- Specifications
  
  546
  - Service Data
    546
- Repair Instructions
  
  547
- Lighting Systems
  
  547
- Specifications
  
  557
  - Service Data
    557
  - Tightening Torque Specifications
    558
- Special Tools and Equipment
  
  558
  - Special Tool
    558
- Combination Meter / Fuel Meter / Horn
  
  559
- General Description
  
  559
  - Combination Meter System Description
    559
- Repair Instructions
  
  560
- Special Tools and Equipment
  
  569
  - Recommended Service Material
    569
  - Special Tool
    569
- Specifications
  
  569
  - Service Data
    569
  - Tightening Torque Specifications
    569
- Schematic and Routing Diagram
  
  570
  - Seat Lock Cable Routing Diagram
    570
- Exterior Parts
  
  570
- Repair Instructions
  
  571
- Specifications
  
  576
  - Tightening Torque Specifications
    576
- Special Tools and Equipment
  
  576
  - Recommended Service Material
    576
- Body Structure
  
  577
- Repair Instructions
  
  577
  - Body Frame Construction
    577
  - Steering Lock Bracket Construction
    578
  - Side-Stand Construction
    578
  - Side-Stand Removal and Installation
    579
- Specifications
  
  579
  - Tightening Torque Specifications
    579
- Special Tools and Equipment
  
  579
  - Recommended Service Material
    579

Suzuki Intruder VZ1500 Owner's Manual (195 pages)

Motorcycle

Brand: Suzuki | Category: Motorcycle | Size: 1 MB

Table of Contents

7
- The Sport of Motorcycling
  10
Fuel, Oil and Coolant Recommendations

19
- Fuel
  20
- Engine Oil
  23
- Engine Coolant Solution
  25
- Final Gear Oil
  25
Controls, Equipment and Adjustments

27
- Controls, Equipment and Adjustments
  28
  - Location of Parts
    28
  - Key
    31
  - Ignition Switch
    32
  - Steering Lock
    33
  - Instrument Panel
    34
  - Left Handlebar
    47
  - Right Handlebar
    50
  - Fuel Tank Cap
    54
  - Gearshift Lever
    56
  - Rear Brake Pedal
    57
  - Seat Lock
    57
  - Helmet Holder
    60
  - Side Stand
    61
  - Suspension Adjustment
    63
- Break-In and Inspection before Riding
  67
Riding Tips

75
- Riding Tips
  76
- Starting the Engine
  76
- Starting off and Shifting
  78
- Using the Transmission
  80
- Riding on Hills
  82
- Stopping and Parking
  82
- Carrying a Passenger
  85
Accessory Use and Motorcycle Loading

87
- Accessory Use
  88
- Accessory Installation Guideline
  89
- Loading Limit
  90
- Loading Guidelines
  91
- Modification
  92
Inspection and Maintenance

93
- Maintenance Schedule
  94
- Notice
  94
- General Lubrication
  99
- Tools
  99
- Battery
  101
- Air Cleaner
  103
- Spark Plug
  110
- Engine Oil
  115
- Throttle Cable Adjustment
  123
- Engine Idle Speed Inspection
  124
- Fuel Hose
  124
- Clutch Adjustment
  126
- Engine Coolant
  128
- Final Gear Oil
  130
- Brakes
  132
- Tires
  139
- Side Stand/Ignition Interlock System
  144
- Front Wheel Removal
  146
- Rear Wheel Removal
  150
- Light Bulb Replacement
  154
- Fuses
  160
- Troubleshooting
  163
  - Troubleshooting
    164
Storage Procedure and Motorcycle Cleaning

167
- Storage Procedure
  168
- Corrosion Prevention
  170
- Procedure for Returning to Service
  170
- Motorcycle Cleaning
  172
- Inspection after Cleaning
  174
Consumer Information

175
- Emission Control Warranty
  176
  - Consumer Information
    176
- Tampering with Noise Control System Prohibited
  177
- On-Board Motorcycle Computer Data Information
  178
- Serial Number Location
  179
- Reporting Safety Defects
  180
- Location of Labels
  181
- Specifications
  184
- Index
  188

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Suzuki Intruder VZ1500 Manuals

Suzuki Intruder VZ1500 Service Manual (580 pages)

Table of Contents

Precautions

Precautions

Special Tools and Equipment

Section 1 Engine

Precautions

General Description

Engine General Information and Diagnosis

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Special Tools and Equipment

Specifications

Engine Electrical Devices

Precautions

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Schematic and Routing Diagram

Engine Mechanical

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Schematic and Routing Diagram

Starting System

Component Location

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions