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Intruder VZR1800
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 (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
Precautions in Servicing
197
Electrical Parts
197
Fuse
198
Ecm/Various Sensors
198
Electrical Circuit Inspection Procedure
200
Using the Multi-Circuit Tester
203
Fi System Technical Features
204
Injection Time (Injection Volume)
204
Compensation of Injection Time (Volume)
205
Injection Stop Control
205
Fi System Parts Location
206
Fi System Wiring Diagram
208
Ecm Terminal
209
Self-Diagnosis Function
211
User Mode
211
Dealer Mode
212
Tps Adjustment
214
Fail-Safe Function
215
Fi System Troubleshooting
216
Customer Complaint Analysis
216
Visual Inspection
217
Self-Diagnostic Procedures
218
Self-Diagnosis Reset Procedure
218
Use of Sds Diagnostic Procedures
219
Use of Sds Diagnosis Reset Procedure
220
Show Data When Trouble (Displaing Data at the Time of Dtc)
221
Malfunction Code and Defective Condition
222
C12" (P0335) Ckp Sensor Circuit Malfunction
226
C13" (P1750-H/L) or "C17" (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
228
C14" (P0120-H/L) Tp Sensor Circuit Malfunction
235
C15" (P0115-H/L) Ect Sensor Circuit Malfunction
240
C21" (P0110-H/L) Iat Sensor Circuit Malfunction
244
C23" (P1651-H/L) to Sensor Circuit Malfunction
248
C28" (P1655) Stv Actuator Circuit Malfunction
252
C29" (P1654-H/L) Stp Sensor Circuit Malfunction
255
C31" (P0705) Gp Switch Circuit Malfunction
260
C32" (P0201) or "C33" (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
262
C40" (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION
264
C41" (P0230-H/L) Fp Relay Circuit Malfunction
270
C42" (P01650) Ig Switch Circuit Malfunction
272
C44" (P0156/P0161) or "C64" (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (for E-02, 19, 24)
273
C46" (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION
277
C49" (P1768) or "C61" (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
286
C60" (P0480) Cooling Fan Relay Circuit Malfunction
288
Sensors
291
Iap Sensor Inspection
291
Iap Sensor Removal and Installation
291
Tp Sensor Inspection
291
Tp Sensor Removal and Installation
291
Tps Adjustment
291
Stp Sensor Inspection
292
Stp Sensor Removal and Installation
292
Stp Sensor Adjustment
292
Ckp Sensor Inspection
292
Ckp Sensor Removal and Installation
292
Iat Sensor Inspection
293
Iat Sensor Removal and Installation
293
Ect Sensor Inspection
293
Ect Sensor Removal and Installation
293
To Sensor Inspection
293
To Sensor Removal and Installation
293
Ho2 Sensor Inspection (for E-02, 19, 24)
294
Ho2 Sensor Removal and Installation (for E-02, 19, 24)
294
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
Fuel Injection System
525
Crankcase Emission Control System
526
Exhaust Emission Control System (Pair System)
527
Noise Emission Control System
528
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 (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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