User Manuals: Suzuki Intruder VZR1800 Power Cruiser

User Manuals: Suzuki Intruder VZR1800 Power Cruiser

Manuals and User Guides for Suzuki Intruder VZR1800 Power Cruiser. We have 2 Suzuki Intruder VZR1800 Power Cruiser manuals available for free PDF download: Service Manual

Suzuki Intruder VZR1800 Service Manual

Suzuki Intruder VZR1800 Service Manual (586 pages)

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

Table of Contents

General Information 1

8
- General Information
  2
- Periodic Maintenance
  2
- Fi System Diagnosis
  2
- Exhaust System
  2
- Electrical System
  2
- Servicing Information
  2
- Wiring Diagram
  2
- How to Use this Manual
  3
- Abbreviations Used in this Manual
  5
- Table of Contents
  8
- Warning/Caution/Note
  9
- General Precautions
  9
- Suzuki Vzr1800K6 ('06-Model)
  11
- Serial Number Location
  11
- Fuel, Oil and Engine Coolant Recommendation
  12
  - Fuel (for Usa and Canada)
    12
  - Fuel (for Other Countries)
    12
  - Engine Oil (for Usa)
    12
  - Engine Oil (for Other Countries)
    12
  - Gear Oil (Final Drive Gear Oil)
    12
  - Brake Fluid
    12
  - Front Fork Oil
    13
  - Engine Coolant
    13
- Break-In Procedures
  14
- Cylinder Identification
  14
- Information Labels
  15
- Specifications
  16
  - Dimensions and Dry Mass
    16
  - Engine
    16
  - Drive Train
    16
Chassis

17
- Capacities
  17
- Electrical
  17
- Periodic Maintenance
  18
- Periodic Maintenance Schedule
  19
  - Periodic Maintenance Chart
    19
  - Lubrication Points
    20
- Maintenance and Tune-Up Procedures
  21
  - Air Cleaner
    21
  - Exhaust Pipe Bolts and Muffler Bolts
    23
  - Exhaust Control Valve
    24
  - Valve Clearance
    25
  - Spark Plug
    30
  - Fuel Line
    33
  - Evaporative Emission Control System (E-33 Only)
    33
  - Engine Oil and Oil Filter
    34
  - Final Gear Oil
    36
  - Throttle Cable Play
    36
  - Pair (Air Supply) System
    36
  - Throttle Valve Synchronization
    37
  - Cooling System
    37
  - Clutch Cable Play
    39
  - Brake
    40
  - Tires
    44
  - Steering
    45
  - Front Fork
    45
  - Rear Suspension
    46
  - Chassis Bolts and Nuts
    46
- Compression Pressure Check
  48
  - Compression Test Procedure
    48
- Oil Pressure Check
  49
- Sds Check
  50
- Data at the Time of Racing
  51
Engine

53
- Engine Components Removable with Engine in Place
  54
- Engine Removal and Installation
  55
  - Engine Removal
    55
  - Engine Installation
    61
- Engine Disassembly
  65
- Engine Components Inspection and Service
  81
  - Cylinder Head Cover
    81
  - Camshaft
    81
  - Camshaft Runout
    83
  - Cam Chain Tension Adjuster
    84
  - Cam Chain Tensioner
    84
  - Cam Chain Guide
    84
  - Cylinder Head and Valve
    84
  - Cylinder
    93
  - Piston and Piston Ring
    94
    
    Piston Diameter
    94
    
    Piston Ring Groove Width
    95
    
    Piston Ring Thickness
    95
    
    Piston Ring End Gap
    95
  - Clutch
    96
  - Gearshift Cover
    98
  - Starter Clutch
    99
  - Oil Pump
    100
  - Starter Torque Limiter
    102
  - Generator Cover
    102
  - Clutch Release Camshaft
    103
  - Water Pump
    104
  - Gearshift
    104
  - Oil Pressure Regulator
    105
  - Oil Strainer
    105
  - Transmission
    106
  - Crankcase
    112
  - Balancer Driven Gear
    119
  - Crankshaft and Conrod
    121
  - Crankshaft Journal Bearing
    125
  - Crankshaft Thrust Bearing
    128
- Engine Reassembly
  130
Driveline/Axle

166
- Secondary Bevel Gears
  167
  - Construction
    167
  - Removal
    169
  - Disassembly
    169
  - Inspection
    171
  - Reassembly
    173
  - Secondary Gear Shims Adjustment
    175
- Final Bevel Gears
  178
  - Construction
    178
  - Final Gear Case Removal
    180
  - Final Gear Case Disassembly
    180
  - Final Gear Shims Adjustment
    185
  - Final Gear Case Reassembly
    189
  - Final Gear Case Installation
    193
Fi System Diagnosis

195
Fuel System and Throttle Body

295
- Fuel Delivery System
  296
- Fuel System
  297
  - Fuel Tank Removal
    297
  - Fuel Tank Installation
    297
  - Fuel Pressure Inspection
    298
  - Fuel Pump Inspection
    299
  - Fuel Discharge Amount Inspection
    299
  - Fuel Pump Relay Inspection
    300
  - Fuel Pump and Fuel Level Gauge Removal
    301
  - Fuel Level Gauge Inspection
    302
  - Fuel Pump Disassembly
    303
  - Fuel Mesh Filter Inspection
    304
  - Fuel Pump and Fuel Level Gauge Reassembly and Installation
    304
- Throttle Body
  306
  - Construction
    306
  - Air Cleaner Box Removal
    307
  - Air Cleaner Box Installation
    307
  - Air Cleaner Chamber and Throttle Body Removal
    307
  - Throttle Body Disassembly
    309
  - Throttle Body Cleaning
    311
  - Inspection
    311
  - Isc Valve Inspection
    311
  - Isc Valve Removal
    312
  - Inspection
    312
  - Isc Valve Installation
    312
  - Throttle Body Reassembly
    313
  - Air Cleaner Chamber and Throttle Body Installation
    315
  - Stp Sensor Adjustment
    316
  - Fuel Injector Removal
    316
  - Fuel Injector Inspection
    316
  - Fuel Injector Installation
    317
  - Throttle Valve Synchronization
    317
  - Throttle Position Sensor (Tps) Setting
    318
Exhaust System

319
- Excva (Exhaust Control Valve Actuator) and Excv (Exhaust Control Valve)
  320
  - Excva and Excv Removal
    320
  - Excva Inspection
    321
  - Excv Inspection
    321
  - Cable Inspection
    321
  - Excva and Excv Installation
    322
  - Excva Adjustment
    324
- Exhaust Pipe and Muffler
  326
  - Removal
    326
  - Installation
    328
Cooling and Lubrication System

331
- Engine Coolant
  332
- Cooling Circuit
  333
  - Cooling Circuit Inspection
    333
- Radiator and Water Hose
  334
  - Radiator Removal and Disassembly
    334
  - Radiator Disassembly
    335
  - Radiator Cap Inspection
    335
  - Radiator Inspection and Cleaning
    336
  - Radiator Reassembly
    336
  - Radiator Installation
    336
  - Water Hose Inspection
    337
- Cooling Fan
  338
  - Inspection
    338
  - Cooling Fan Relay Inspection
    338
- Ect Sensor
  339
  - Removal
    339
  - Inspection
    339
  - Installation
    340
- Thermostat
  341
  - Removal
    341
  - Inspection
    341
  - Installation
    342
- Water Pump
  343
  - Removal and Disassembly
    343
  - Inspection
    345
  - Reassembly and Installation
    346
Chassis

350
Electrical System

426
- Electrical
  428
Servicing Information

471
- Engine Lubrication System Chart
  349
  - Exterior Parts
    352
    
    Fastener Removal and Installation
    352
    
    Front and Rear Seat
    353
    
    Frame Side Cover
    354
    
    Rear Frame Cover
    354
    
    Frame Head Cover and Radiator Cover
    355
  - Front Wheel
    357
    
    Construction
    357
    
    Removal
    358
    
    Inspection and Disassembly
    358
    
    Reassembly and Installation
    360
  - Front Fork
    363
    
    Construction
    363
    
    Removal and Disassembly
    364
    
    Inspection
    367
    
    Reassembly
    368
    
    Installation
    371
  - Steering
    372
    
    Construction
    372
    
    Removal
    373
    
    Inspection and Disassembly
    374
    
    Reassembly
    375
    
    Installation
    375
    
    Steering Tension Adjustment
    377
  - Handlebars
    378
    
    Construction
    378
    
    Removal
    379
    
    Installation
    380
  - Rear Wheel
    382
    
    Construction
    382
    
    Removal
    383
    
    Disassembly
    383
    
    Inspection and Disassembly
    384
    
    Reassembly and Installation
    385
  - Rear Suspension
    389
    
    Construction
    389
    
    Removal
    390
    
    Inspection and Disassembly
    391
    
    Rear Shock Absorber Disposal
    394
    
    Reassembly
    395
    
    Installation
    398
    
    Suspension Setting
    399
  - Front Brake
    400
    
    Construction
    400
    
    Brake Pad Replacement
    401
    
    Brake Fluid Replacement
    402
    
    Caliper Removal
    403
    
    Caliper Disassembly
    404
    
    Caliper Inspection
    405
    
    Caliper Reassembly
    405
    
    Caliper Installation
    407
    
    Brake Disc Inspection
    407
    
    Master Cylinder Removal and Disassembly
    408
    
    Master Cylinder Inspection
    409
    
    Master Cylinder Reassembly
    409
    
    Master Cylinder Installation
    410
  - Rear Brake
    411
    
    Construction
    411
    
    Brake Pad Replacement
    412
    
    Brake Fluid Replacement
    413
    
    Caliper Removal
    414
    
    Caliper Disassembly
    414
    
    Caliper Inspection
    415
    
    Caliper Reassembly
    417
    
    Caliper Installation
    418
    
    Master Cylinder Removal
    418
    
    Master Cylinder Disassembly
    419
    
    Master Cylinder Inspection
    420
    
    Master Cylinder Reassembly
    420
    
    Master Cylinder Installation
    421
  - Tire and Wheel
    422
    
    Tire Removal
    422
    
    Inspection
    422
    
    Valve Inspection
    423
    
    Tire Installation
    424
    
    Balancer Weight Installation
    425
    
    Electrical System
    426
  - Fuse
    428
  - Cautions in Servicing
    428
    
    Connector
    428
    
    Coupler
    428
    
    Clamp
    428
    
    Semi-Conductor Equipped Part
    429
    
    Battery
    429
    
    Connecting the Battery
    429
    
    Wiring Procedure
    429
    
    Using the Multi-Circuit Tester
    430
  - Location of Electrical Components
    431
  - Charging System
    433
    
    Troubleshooting
    433
    
    Inspection
    434
  - Starter System and Side-Stand/Ignition Interlock System
    437
    
    Troubleshooting
    437
    
    Starter Motor Removal
    439
    
    Starter Motor Disassembly
    440
    
    Starter Motor Inspection
    441
    
    Starter Motor Reassembly
    442
    
    Starter Relay Inspection
    443
    
    Side Stand/Ignition Interlock System Parts Inspection
    444
  - Ignition System
    447
    
    Troubleshooting
    448
    
    Inspection
    450
  - Speedometer and Tachometer
    455
    
    Description
    455
    
    Speedometer Removal and Disassembly
    456
    
    Tachometer Removal and Disassembly
    457
    
    Inspection
    458
  - Position Light
    464
  - Lamps
    464
    
    Headlight, Brake Light/Taillight, License Plate Light and Turn Signal Light
    464
    
    Headlight Relay Inspection
    465
  - Relays
    466
    
    Turn Signal/Side-Stand Relay
    466
    
    Starter Relay
    466
    
    Fuel Pump Relay
    466
    
    Cooling Fan Relay
    466
    
    Switches Inspection
    467
  - Battery
    468
    
    Specifications
    468
    
    Initial Charging
    468
    
    Servicing
    470
    
    Recharging Operation
    470
    
    Servicing Information
    471
  - Troubleshooting
    473
    
    Fi System Malfunction Code and Defective Condition
    473
    
    Engine
    477
    
    Radiator (Cooling System)
    483
    
    Chassis
    484
    
    Shaft Drive
    485
    
    Brakes
    485
    
    Electrical
    486
    
    Battery
    487
    
    Special Tools
    488
  - Tightening Torque
    492
    
    Engine
    492
    
    Fi System and Intake Air System
    493
    
    Cooling System
    493
    
    Chassis
    494
    
    Tightening Torque Chart
    495
  - Service Data
    496
  - Front Turn Signal/Position Light
    502
  - Front Turn Signal Light
    502
  - Rear Turn Signal Light
    502
  - License Light
    502
  - Brake Light/Taillight
    502
  - Fuel Level Indicator Light
    502
  - Turn Signal Indicator Light
    502
  - Neutral Indicator Light
    502
  - High Beam Indicator Light
    502
  - Coolant Temperature/Oil Pressure Indicator Light
    502
  - Fuel Tank Capacity
    504
  - L (4.9/4.1 Us/Lmp Gal)
    504
    
    Tire Pressure
    504
    
    Suspension
    504
    
    Fuel + Oil
    504
  - Wiring Harness, Cable and Hose Routing
    505
    
    Wiring Harness Routing
    505
    
    Engine Electrical Parts Lead Wire Routing
    507
    
    Cable Routing
    508
    
    Front Brake Hose Routing
    509
    
    Rear Brake Hose Routing
    510
    
    Throttle Body Hose Routing
    511
    
    Cooling System Hose Routing
    512
    
    Pair (Air Supply) System Hose Routing (for E-03, 28, 33)
    513
    
    Pair (Air Supply) System Hose Routing (for the Others)
    514
    
    Fuel Tank Installation
    515
    
    Frame Head Cover and Radiator Cover Installation
    516
    
    Frame Head Cover Cushion Installation
    517
    
    Radiator Upper Cover Cushion Installation
    517
    
    Left Frame Covers Installation
    518
    
    Right Frame Covers Installation
    519
    
    Headlight Cover Installation
    520
    
    Ignition Coil Installation
    521
    
    Side-Stand Installation
    521
    
    Rear Turn Signal Light, License Light Wire Routing
    522
    
    Seat Lock Cable Routing
    522
    
    License Light and License Plate Installation
    523
    
    Brake Light/Taillight Installation
    523
- Capacities
  504
Emission Control Information

524
- Emission Control Systems
  525
- Inspection
  529
  - Pair Hoses
    529
  - Pair Reed Valve
    529
  - Pair Control Solenoid Valve
    529
- Pair (Air Supply) System and Emission Control System
  529
- Pair (Air Supply) System Hose Routing (for E-03, 28, 33)
  531
- Pair (Air Supply) System Hose Routing (for the Others)
  532
- Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)
  533
  - Wiring Diagram
    534
  - Bearing
    542
  - Spacer
    543

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Suzuki Intruder VZR1800 Service Manual

Suzuki Intruder VZR1800 Service Manual (50 pages)

Brand: Suzuki | Category: Motorcycle | Size: 3 MB

Table of Contents

Table of Contents
2
Information Labels
4
Specifications
5
- Dimensions and Curb Mass
  5
- Lubrication Points
  6
Engine Components Inspection and Servicing
7
- Camshaft
  7
- Clutch
  8
- Crankshaft Journal Bearing
  10
Driveline/Axle
11
- Secondary Gear Shims
  11
- Universal Joint Installation
  11
Fi System
12
- Fi System Parts Location
  12
Exhaust System
14
- Construction
  14
Front Fork
15
- Construction
  15
- Removal and Disassembly
  16
- Inspection
  19
- Reassembly
  20
- Installation
  23
Steering
24
- Construction
  24
Rear Brake Caliper and Bracket
25
- Installation
  25
Charging System
25
- Inspection
  25
Speedometer and Tachometer
26
- Description
  26
- Tachometer Removal and Disassembly
  27
Headlight Housing/Tachometer and Headlight Cover Brace
30
- Removal
  30
- Installation
  31
Battery Ground Wire
32
- Installation
  32
Tightening Torque
33
- Engine
  33
- Driveline/Axle
  33
- Chassis
  33
Service Data
33
Wiring Diagram
36
Wiring Harness Routing
37
Cable Routing
39
Front Brake Hose Routing
40
Rear Brake Hose Routing
41
Cooling System Hose Routing
42
Fuel Tank Installation
43
Left Frame Covers Installation
44
Right Frame Covers Installation
45
Headlight Cover Installation
46
Front Turn Signal Light Installation
47
Secondary Gear Case Cover Damper Installation
48
Rear Fender Cushion Installation
48

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