Suzuki Intruder VZR1800 Manuals
Manuals and User Guides for Suzuki Intruder VZR1800. We have 2 Suzuki Intruder VZR1800 manuals available for free PDF download: Service Manual
Suzuki Intruder VZR1800 Service Manual (586 pages)
Brand: Suzuki | Category: Motorcycle | Size: 19.89 MB
Table of contents
General Information2................................................................................................................................................................
Periodic Maintenance2................................................................................................................................................................
Fi System Diagnosis2................................................................................................................................................................
Exhaust System2................................................................................................................................................................
Electrical System2................................................................................................................................................................
Servicing Information2................................................................................................................................................................
Wiring Diagram2................................................................................................................................................................
How To Use This Manual3................................................................................................................................................................
Abbreviations Used In This Manual5................................................................................................................................................................
General Precautions9................................................................................................................................................................
Serial Number Location11................................................................................................................................................................
Brake Fluid12................................................................................................................................................................
Front Fork Oil13................................................................................................................................................................
Cylinder Identification14................................................................................................................................................................
Information Labels15................................................................................................................................................................
Periodic Maintenance Schedule19................................................................................................................................................................
Periodic Maintenance Chart19................................................................................................................................................................
Lubrication Points20................................................................................................................................................................
Air Cleaner21................................................................................................................................................................
Exhaust Pipe Bolts And Muffler Bolts23................................................................................................................................................................
Valve Clearance25................................................................................................................................................................
Spark Plug30................................................................................................................................................................
Fuel Line33................................................................................................................................................................
Evaporative Emission Control33................................................................................................................................................................
Engine Oil And Oil Filter34................................................................................................................................................................
Final Gear Oil36................................................................................................................................................................
Throttle Cable Play36................................................................................................................................................................
Rear Suspension46................................................................................................................................................................
Chassis Bolts And Nuts46................................................................................................................................................................
Compression Pressure Check48................................................................................................................................................................
Oil Pressure Check49................................................................................................................................................................
Sds Check50................................................................................................................................................................
Data At The Time Of Racing51................................................................................................................................................................
Engine Installation61................................................................................................................................................................
Engine Disassembly65................................................................................................................................................................
Engine Components Inspection And Service81................................................................................................................................................................
Cylinder Head Cover81................................................................................................................................................................
Camshaft Runout83................................................................................................................................................................
Cam Chain Tension Adjuster84................................................................................................................................................................
Cam Chain Tensioner84................................................................................................................................................................
Cam Chain Guide84................................................................................................................................................................
Cylinder Head And Valve84................................................................................................................................................................
Piston And Piston Ring94................................................................................................................................................................
Piston Diameter94................................................................................................................................................................
Piston Ring Groove Width95................................................................................................................................................................
Piston Ring Thickness95................................................................................................................................................................
Piston Ring End Gap95................................................................................................................................................................
Gearshift Cover98................................................................................................................................................................
Starter Clutch99................................................................................................................................................................
Oil Pump100................................................................................................................................................................
Starter Torque Limiter102................................................................................................................................................................
Generator Cover102................................................................................................................................................................
Clutch Release Camshaft103................................................................................................................................................................
Oil Pressure Regulator105................................................................................................................................................................
Oil Strainer105................................................................................................................................................................
Crankshaft And Conrod121................................................................................................................................................................
Crankshaft Journal Bearing125................................................................................................................................................................
Crankshaft Thrust Bearing128................................................................................................................................................................
Engine Reassembly130................................................................................................................................................................
Final Gear Case Installation193................................................................................................................................................................
Precautions In Servicing197................................................................................................................................................................
Electrical Parts197................................................................................................................................................................
Electrical Circuit Inspection Procedure200................................................................................................................................................................
Fi System Technical Features204................................................................................................................................................................
Injection Stop Control205................................................................................................................................................................
Fi System Parts Location206................................................................................................................................................................
Fi System Wiring Diagram208................................................................................................................................................................
Ecm Terminal209................................................................................................................................................................
User Mode211................................................................................................................................................................
Dealer Mode212................................................................................................................................................................
Fi System Troubleshooting216................................................................................................................................................................
Visual Inspection217................................................................................................................................................................
Use Of Sds Diagnostic Procedures219................................................................................................................................................................
Show Data When Trouble221................................................................................................................................................................
Displaing Data At The Time Of Dtc221................................................................................................................................................................
Malfunction Code And Defective Condition222................................................................................................................................................................
Iap Sensor Inspection291................................................................................................................................................................
Iap Sensor Removal And Installation291................................................................................................................................................................
Tp Sensor Inspection291................................................................................................................................................................
Tp Sensor Removal And Installation291................................................................................................................................................................
Stp Sensor Inspection292................................................................................................................................................................
Ckp Sensor Inspection292................................................................................................................................................................
Ckp Sensor Removal And Installation292................................................................................................................................................................
Iat Sensor Inspection293................................................................................................................................................................
Iat Sensor Removal And Installation293................................................................................................................................................................
Ect Sensor Inspection293................................................................................................................................................................
Ect Sensor Removal And Installation293................................................................................................................................................................
To Sensor Inspection293................................................................................................................................................................
To Sensor Removal And Installation293................................................................................................................................................................
Fuel System And Throttle Body295................................................................................................................................................................
Fuel Delivery System296................................................................................................................................................................
Fuel System297................................................................................................................................................................
Fuel Tank Removal297................................................................................................................................................................
Fuel Pressure Inspection298................................................................................................................................................................
Fuel Pump Inspection299................................................................................................................................................................
Fuel Discharge Amount Inspection299................................................................................................................................................................
Fuel Pump Relay Inspection300................................................................................................................................................................
Fuel Pump Disassembly303................................................................................................................................................................
Air Cleaner Box Removal307................................................................................................................................................................
Air Cleaner Box Installation307................................................................................................................................................................
Throttle Body Disassembly309................................................................................................................................................................
Throttle Body Cleaning311................................................................................................................................................................
Isc Valve Inspection311................................................................................................................................................................
Isc Valve Removal312................................................................................................................................................................
Isc Valve Installation312................................................................................................................................................................
Throttle Body Reassembly313................................................................................................................................................................
Fuel Injector Removal316................................................................................................................................................................
Fuel Injector Inspection316................................................................................................................................................................
Fuel Injector Installation317................................................................................................................................................................
Excva Inspection321................................................................................................................................................................
Excv Inspection321................................................................................................................................................................
Cable Inspection321................................................................................................................................................................
Excva Adjustment324................................................................................................................................................................
Cooling And Lubrication System331................................................................................................................................................................
Cooling Circuit333................................................................................................................................................................
Cooling Circuit Inspection333................................................................................................................................................................
Radiator Cap Inspection335................................................................................................................................................................
Radiator Inspection And Cleaning336................................................................................................................................................................
Radiator Installation336................................................................................................................................................................
Water Hose Inspection337................................................................................................................................................................
Cooling Fan338................................................................................................................................................................
Cooling Fan Relay Inspection338................................................................................................................................................................
Ect Sensor339................................................................................................................................................................
Engine Lubrication System Chart349................................................................................................................................................................
Chassis350................................................................................................................................................................
Exterior Parts352................................................................................................................................................................
Rear Frame Cover354................................................................................................................................................................
Front Wheel357................................................................................................................................................................
Steering Tension Adjustment377................................................................................................................................................................
Rear Wheel382................................................................................................................................................................
Rear Shock Absorber Disposal394................................................................................................................................................................
Suspension Setting399................................................................................................................................................................
Front Brake400................................................................................................................................................................
Master Cylinder Removal And Disassembly408................................................................................................................................................................
Rear Brake411................................................................................................................................................................
Master Cylinder Disassembly419................................................................................................................................................................
Tire And Wheel422................................................................................................................................................................
Tire Removal422................................................................................................................................................................
Valve Inspection423................................................................................................................................................................
Tire Installation424................................................................................................................................................................
Balancer Weight Installation425................................................................................................................................................................
Cautions In Servicing428................................................................................................................................................................
Connecting The Battery429................................................................................................................................................................
Location Of Electrical Components431................................................................................................................................................................
Charging System433................................................................................................................................................................
Starter Motor Removal439................................................................................................................................................................
Starter Motor Disassembly440................................................................................................................................................................
Starter Motor Inspection441................................................................................................................................................................
Starter Motor Reassembly442................................................................................................................................................................
Starter Relay Inspection443................................................................................................................................................................
Ignition System447................................................................................................................................................................
Speedometer And Tachometer455................................................................................................................................................................
Speedometer Removal And Disassembly456................................................................................................................................................................
Tachometer Removal And Disassembly457................................................................................................................................................................
Headlight Relay Inspection465................................................................................................................................................................
Starter Relay466................................................................................................................................................................
Fuel Pump Relay466................................................................................................................................................................
Switches Inspection467................................................................................................................................................................
Initial Charging468................................................................................................................................................................
Recharging Operation470................................................................................................................................................................
Fi System Malfunction Code And Defective Condition473................................................................................................................................................................
Troubleshooting473................................................................................................................................................................
Shaft Drive485................................................................................................................................................................
Special Tools488................................................................................................................................................................
Tightening Torque492................................................................................................................................................................
Fi System And Intake Air System493................................................................................................................................................................
Tire Pressure504................................................................................................................................................................
Suspension504................................................................................................................................................................
Fuel + Oil504................................................................................................................................................................
Wiring Harness Routing505................................................................................................................................................................
Cable Routing508................................................................................................................................................................
Front Brake Hose Routing509................................................................................................................................................................
Rear Brake Hose Routing510................................................................................................................................................................
Cooling System Hose Routing512................................................................................................................................................................
Frame Head Cover Cushion Installation517................................................................................................................................................................
Left Frame Covers Installation518................................................................................................................................................................
Right Frame Covers Installation519................................................................................................................................................................
Headlight Cover Installation520................................................................................................................................................................
Seat Lock Cable Routing522................................................................................................................................................................
Emission Control Information524................................................................................................................................................................
Emission Control Systems525................................................................................................................................................................
Fuel Injection System525................................................................................................................................................................
Crankcase Emission Control System526................................................................................................................................................................
Noise Emission Control System528................................................................................................................................................................
Pair Reed Valve529................................................................................................................................................................
Pair Control Solenoid Valve529................................................................................................................................................................
Bearing542................................................................................................................................................................
Spacer543................................................................................................................................................................
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Suzuki Intruder VZR1800 Service Manual (50 pages)
Brand: Suzuki | Category: Motorcycle | Size: 3.51 MB
Table of contents
Table Of Contents2................................................................................................................................................................
Specifications5................................................................................................................................................................
Lubrication Points6................................................................................................................................................................
Engine Components Inspection And Servicing7................................................................................................................................................................
Clutch8................................................................................................................................................................
Crankshaft Journal Bearing10................................................................................................................................................................
Driveline/axle11................................................................................................................................................................
Fi System Parts Location12................................................................................................................................................................
Exhaust System14................................................................................................................................................................
Front Fork15................................................................................................................................................................
Removal And Disassembly16................................................................................................................................................................
Inspection19................................................................................................................................................................
Reassembly20................................................................................................................................................................
Installation23................................................................................................................................................................
Steering24................................................................................................................................................................
Charging System25................................................................................................................................................................
Speedometer And Tachometer26................................................................................................................................................................
Tachometer Removal And Disassembly27................................................................................................................................................................
Headlight Housing/tachometer And Headlight Cover Brace30................................................................................................................................................................
Battery Ground Wire32................................................................................................................................................................
Tightening Torque33................................................................................................................................................................
Service Data33................................................................................................................................................................
Wiring Diagram36................................................................................................................................................................
Wiring Harness Routing37................................................................................................................................................................
Cable Routing39................................................................................................................................................................
Front Brake Hose Routing40................................................................................................................................................................
Rear Brake Hose Routing41................................................................................................................................................................
Cooling System Hose Routing42................................................................................................................................................................
Fuel Tank Installation43................................................................................................................................................................
Left Frame Covers Installation44................................................................................................................................................................
Right Frame Covers Installation45................................................................................................................................................................
Headlight Cover Installation46................................................................................................................................................................
Front Turn Signal Light Installation47................................................................................................................................................................
Secondary Gear Case Cover Damper Installation48................................................................................................................................................................