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Suzuki VL1500 Manuals
Manuals and User Guides for Suzuki VL1500. We have
3
Suzuki VL1500 manuals available for free PDF download: Service Manual, Supplementary Service Manual, Technische Tekeningen Manual
Suzuki VL1500 Service Manual (410 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 35.86 MB
Table of Contents
Introduction
2
Group Index
2
Symbol
3
How to Use this Manual
4
To Locate What You Are Looking for
4
Component Parts and Work Tto be Done
4
General Information/Contents
5
Warning/Caution/Note
6
General Precautions
6
Suzuki VL1500W (98-Model) Product View
8
Serial Number Location
8
Fuel Recommendation
8
Break-In Procedures
9
Cylinder Identification
9
Engine/Gear/Front Fork Oil
9
Brake Fluid
9
Information Labels
10
Specifications
11
Country and Area Codes
13
Periodic Maintenants Contents
15
Periodic Maintenance Schedule/Chart
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Spark Plugs
18
Air Cleaner
19
Carbon Deposits
19
Spark Plug Gap/Cap Installation
19
Electrode's Condition
19
Engine Oil/Oil Filter Replacement
21
Fuel Hose
22
Necessary Amount of Engine Oil
22
Fuel Strainer
23
Engine Idle Speed
23
Automatic Decompression Cable
23
Rear/Front Cylinder Head View
24
Throttle Cable Play
25
Carbretor Synchronization
25
Evaporative Emission Control System (E-33 Only)
25
Pair (Air Supply System E-33 Only)
25
Clutch Hose and Clutch Fluid
26
Clutch Fluid Level
26
Air Bleeding the Brake Fluid Circuit
26
Brake Hose and Brake Fluid
27
Brake Fluid Level Check
27
Brake Pads
27
Final Gear Oil
29
Brake Pedal Height
29
Brake Light Switch
29
Tire Tread Condition
29
Steering
30
Front Fork
30
Tire Pressure
30
Rear Suspension
31
Exhaust Pipe Bolts and Muffler Bolts
31
Chassis Bolts and Nuts
32
Compression Pressure Check/Specification
34
Compression Test Procedure
34
Oil Pressure Check/Test Procedure
35
Oil Pressure Specification
35
Low/High Oil Pressure
35
Engine/Contents
36
Engine Components Removable with Engine in Place
37
Engine Left/Right/Center Side
37
Engine Removal
38
Engine Installation
47
Exhaust Gas Sealer
51
Engine Disassembly
52
Engine Reassembly
67
Drive/Driven Plate
84
Front/Rear Cylinder Head
89
Front/Rear Cylinder Head Cover
93
Camshaft/Cylinder Head/Cylinder Head Cover Contents
97
Camshaft/Cylinder Head/Cylinder Head Cover Removal/Servicing
98
Cylinder Head Cover Disassembly
98
Cylinder Head Cover Distortion
99
Rocker Arm Shaft O.D.
99
Rocker Arm I.D.
100
Lash Adjuster
100
De-Compression Shaft
101
Cylinder Head Cover Reassembly
101
Camshafts
103
Cam Wear
103
Camshaft Journal Wear
103
Camshaft Runout
104
Cylinder Head
105
Cylinder Head Distortion
105
Valve Stem Deflection/Wear
107
Valve Guide Servicing
107
Valve Seat Width
108
Valve Seat Servicing
109
Valve Spring
110
Cylinder Head Reassembly
111
Camshaft/Cylinder Head/Cylinder Head Cover Installation
112
Intake/Exhaust Pipe
112
Cylinder/Piston Exploded View
113
Cylinder/Piston Contents
113
Cylinder/Piston Removal/Servicing
114
Cam Chain Tensioner Removal
114
Cylinder Distortion/Bore
114
Piston Diameter
115
Piston to Cylinder Clearance
115
Piston Ring to Groove Clearance
115
Piston Ring Free End Gap and Piston Ring End Gap
116
Piston Pin and Pin Bore
116
Piston Ring Installation
117
Cam Chain Tensioner Adjuster
118
Cam Chain Guide/Tensioner
118
Cylinder/Piston Installation
119
Cam Chain Tension Adjuster Installation
119
Clutch Exploded View
120
Clutch Contents
120
Clutch Removal
121
Clutch Release Cylinder Removal and Disassembly
122
Clutch/Clutch Release Cylinder Inspection
123
Clutch Drive/Driven Plates
123
Clutch Spring Free Length
123
Clutch Installation
124
Clutch Release Bearing
124
Clutch Push Rod
124
Clutch Release Cylinder Inspection
124
Clutch Release Cylinder Reassembly and Installation
126
Starter System/ Generator/Signal Generator Exploded View
127
Starter System/ Generator/Signal Generator Contents
127
Starter Torque Limiter/Generator/Signal Generator Removal
128
Starter Torque Limiter/Limiter Shaft Bush Inspection
130
Generator Stator and Signal Generator Servicing
131
Starter Clutch Inspection
131
Starter Driven Gear Bearing Inspection
131
Starter Clutch Servicing
132
Starter Torque Limiter/Generator/Signal Generator Installation
133
Starter Motor View
135
Gearshift Linkage Exploded View
136
Gearshift Linkage Contents
136
Gearshift Linkage Removal
137
Gearshift Shaft/Gearshift Arm Disassembly/Inspection
139
Return Springs Inspection
139
Gershift Shaft/Gearshift Arm Reassembly
139
Oil Seal Inspection/Replacement
140
Gearshift Shaft Hole Inspection
140
Gearshift Linkage Installation
141
Crankcase/Transmission/Crankshaft/Conrod Exploded View
144
Transmission/Crankshaft/Conrod Removal
145
Transmission Inspection and Service
145
Gearshift Fork to Groove Clearance
145
Countershaft Disassembly
146
Countershaft Reassembly
148
Conrod/Crankshaft Inspection
152
Conrod-Crank Pin Bearing Inspection and Service
152
Conrod Small End ID
152
Conrod Big End Side Clearance
152
Conrod-Crank Pin Bearing Selection
153
Bearing Assembly
154
Conrod ID Specification
154
Crank Pin OD Specification
154
Bearing Thickness
154
Crankcase-Crankshaft Bearing Inspection
155
Crankshaft Thrust Clearance Adjustment
156
Transmission/Crankshaft/Conrod Installation
157
Engine Lubrication System Exploded View
158
Engine Lubrication System Contents
158
Oil Pump and Oil Sump Filter Removal/Disassembly/Inspection
159
Oil Sump Filter Cleaning/Reassembly/Installation
160
Oil Pressure Regulator Removal/Inspection
161
Oil Pressure Regulator Installation
162
Oil Pressure Switch/Oil Cooler Removal
163
Oil Pressure Switch Inspection
163
Oil Cooler Hose Inspection
164
Oil Cooler Inspection/Cleaning/Installaton
164
Oil Jets (for Transmission) Removal
165
Oil Jets (for Secondary Bevel Gears) Removal
166
Oil Jets (for Real Cylinder Head Cooling and Rear Cylinder Head) and Oil Jets (for Piston Cooling) Removal/Inspection/Installation
167
Oil Jet (for Secondary Bevel Gears) Installation
168
Oil Jet (for Transmission) Installation
169
Engine Lubrication System Chart
170
Engine Lubrication System
171
Rear Cylinder View
172
Cylinder Head Cooling System Chart
173
Cylinder Head Cooling System
174
Shaft Drive/Contents
175
Shaft Drive Construction
176
Secondary Bevel Gears Construction
177
Secondary Drive Bevel Gear Removal/Disassembly
179
Secondary Driven Bevel Gear Removal
180
Secondary Driven Bevel Gear Inspection
181
Secondary Gear Shims Adjustment
181
Damper Spring
181
Backlash
181
Tooth Contact
183
Secondary Driven Bevel Gear Installation
185
Secondary Driven Bevel Gear Reassembly
186
Secondary Drive Bevel Gear Installation
186
Final Bevel Gears Construction
187
Final Gear Case Breather Circuit
189
Air/Oil Passage
189
Final Gear Case Removal/Disassembly
190
Final Gear Case Inspection
194
Final Gear Bearing Case Shim Clearance
195
Backlash too Large/Small
196
Final Gear Case Reassembly
198
Final Gear Case Installation
202
Fuel System/Contents
203
Fuel System
204
Fuel Tank Removal
205
Fuel Tank Remounting
206
Fuel Pump Removal
207
Fuel Pump Inspection/Remounting
208
Fuel Strainer Removal
208
Fuel Strainer Inspection/Installation
209
Fuel Level Gauge Removal/Inspection/Installation
209
Fuel-Vapor Separator and Fuel Shut-Off Valve Removal/Inspection/Installation
210
Fuel Tank Inlet Valve Removal
210
Fuel Tank Inlet Valve Inspection/Installation
211
TPC (Tank Pressure Control) Valve Removal/Inspection/Installation
211
Carburetor Construction
212
Fuel System Specifications
213
ID no Location
214
Diaphragm and Piston Operation
215
Lower/Upper Position of the Piston Valve
215
Slow System
216
Transient Enrichment System
216
Main System
217
Starter (Enricher) System
218
Float System
218
Float System Removal
219
Float System Disassembly
220
Carburetor Cleaning/Inspection
225
Needle Valve Inspection
225
Carburetor Reassembly and Remounting
226
Float Height Adjustment
226
Throttle Position Sensor Inspection
226
Throttle Valve
226
Coasting Valve
227
Funnel
227
Pilot Screw
227
Starter Plunger
227
Throttle Position Sensor Positioning
228
Carburetor Engaging
228
Carburetor Clamps
229
Carburetor Synchronization
230
Calibrating each Gauge
230
Chassis Contents
233
Exterior Parts Construction
234
Seat Removal
235
Frame Cover
235
Frame Head Cover and Upper Cover
236
Meter and Fuel Inlet Cover
236
Seat Remounting
237
Rear Fender
237
Front Wheel Construction
238
Front Wheel Removal
240
Front Wheel/Wheel Bearings Inspection and Disassembly
241
Front Wheel Reassembly and Remounting
242
Wheel Axle/Bearing
242
Brake Disc
242
Front Fork Construction
244
Front Fork Removal and Disassembly
245
Front Fork Reassembly and Remounting
248
Inner and Outer Tube Inspection
248
Fork Spring and Damper Rod Ring Inspection
248
Slide Metals and Oil and Dust Seals
248
Damper Rod
249
Fork Oil/Spring
250
Front Forks Remounting
250
Steering Construction
252
Steering Removal and Disassembly
252
Steering Inspection and Disassembly
255
Steering Stem Reassembly and Remounting
256
Outer Races
256
Bearings
256
Steering Stem Nut
256
Handlebar Holder
257
Steering Stem Upper Bracket
257
Front Fork and Steering Stem Head Nut
258
Handlebars
258
Steering Tension Adjustment
259
Rear Wheel Construction
260
Rear Wheel Removal
262
Rear Wheel Disassembly
263
Inspection and Disassembly
263
Rear Wheel Reassembly and Remounting
264
Wheel Bearing/Damper
264
Driven Joint
265
Rear Wheel
265
Rear Suspension Construction
266
Rear Suspension Removal
268
Rear Suspension Inspection and Disassembly
270
Spacer
270
Swingarm Bearing
270
Cushion Lever Bearing
271
Shock Absorber
271
Spring Pre-Load Adjustment
271
Rear Suspension Reassembly
272
Rear Suspension Remounting
273
Swingarm
273
Shock Absorber and Cushionlever Mounting Nut
274
Final Gear Case
274
Front Brake Construction
276
Brake Pad/Fluid Replacement
277
Brake Caliper Removal and Disassembly
278
Brake Caliper Inspection/Reassembly/Remounting
279
Brake Caliper Pistons
279
Brake Disc Inspection
280
Master Cylinder Removal and Disassembly
281
Master Cylinder Inspection/Reassembly/Remounting
282
Piston
282
Rubber Parts
282
Rear Brake Construction
284
Clutch Release/Master Cylinder Construction
291
Clutch Fluid Replacement
292
Clutch Release Cylinder Inspection/Reassembly/Remounting
293
Clutch Master Cylinder Removal and Disassembly
295
Clutch Master Cylinder Inspection/Reassembly/Remounting
296
Tire Removal
298
Tire Inspection
300
Wheels/Tires/Valve Inspection
300
Tire/Valve Installation
301
Tire Presssure
302
Electrical System Contents
303
Cautions in Servicing
304
Connector,Coupler, Clamps and Fuse
304
Semi-Conductor Equipped Parts
304
Battery
305
Connecting Battery
305
Wiring Procedure
305
Using Multi Circuit Tester
305
Location of Electrical Components
306
Charging System Description
308
Charging System Function of Regulator
308
Battery Runs down Quickly
310
Battery Current Leak Inspection
311
Charging Output Inspection
311
Generator Coil Resistance Inspection
312
Generator No-Load Performance Inspection
312
Regulator/Rectifier Inspection
312
Automatic De-Compression System and Starter System Description/Operation
313
Side-Stand/Ignition Interlock System Description/Operation
314
Starter Motor will Not Run
315
Starter Motor Is Hard to Run
316
Starter Motor Removal and Disassembly
317
Carbon Brushes
318
Commutator
318
Armature Coil/Oil Seal Inspection
318
Bearing Inspection
318
Starter Motor Reassembly and Installation
319
Starter Relay Inspection
320
Side-Stand/Ignition Interlock System Part Inspection
321
Neutral Switch
321
Side-Stand Switch
322
Turn Signal/Side-Stand Relay
322
Side-Stand Relay Inspection
322
Automatic De-Compression Relay Inspection
323
Diode Inspection
323
Automatic De-Compression Solenoid Inspection
324
Ignition System (Digital Ignitor) Description
325
No Spark or Poor Spark
326
Ignition Coil Primary Peak Voltage
327
Ignition Coil Resistance
328
Signal Generator Peak Voltage
329
Signal Generator
330
Map (Boost) Sensor Inspection
331
Speedometer Removal/Inspection
332
Fuel Level Indicator Light Inspection
333
Fel Level Gauge Inspection
334
Speedometer/Speed Sensor Inspection
334
Starter Relay
335
Automatic De-Compression Relay
335
Turn Signal Side-Stand Relay
335
Oil Pressure Indicator Inspection
335
Headlight Bulb Replacement
336
Brake Light/Taillight
337
Turn Signal Lights
337
Switches
338
Battery Specificatons
339
Initial Charging
339
Filling Electrolyte
339
Battery Servicing
340
Recharging Operation
341
Servicing Information Contents
342
Engine Troubleshooting
343
Shaft Drive Troubleshooting
346
Carburetor/Chassis Troubleshooting
347
Brakes Troubleshooting
348
Electrical Troubleshooting
349
Battery Troubleshooting
350
Wiring Diagram for E-03/28/33
351
Wiring Diagram for E-02/04/17/18/22/25/34
352
Wiring Diagram for E-24
353
Wire Harness Routing
354
Cable and Hose Routing
357
Fuel System Hose Routing
358
Front Brake Hose Routing
359
Rear Brake Hose Routing
360
Pair (Air Supply) System Hose Routing
361
Engine Side Box
361
Upper Covers, Meter and Fuel Inlet Cover Set-Up
362
Frame Head and Frame Cover Cushion
363
Frame Cover Shield
363
Brake Light/Taillight Set-Up
364
Special Tools
365
Engine Tightening Torque
368
Secondary and Final Tightening Torque
369
Chassis Tightening Torque
370
Tightening Torque Chart
371
Valve and Guide Service Data
372
Camshaft and Cylinder Head Service Data
373
Cylinder/Piston/Piston Ring Service Data
373
Conrod/Crankshaft Service Data
374
Oil Pump/Clutch/Transmission Service Data
375
Shaft Drive/Carburetor Service Data
376
Electrical Service Data
377
Wattage Service Data
378
Brake/Wheel Service Data
378
Suspension/Tire Pressure Service Data
379
Fuel/Oil Service Data
380
Emission Control Information Contents
381
Emission Control Carburetor Components
382
Evaporative Emission Control System (California Model Only)
383
Canister Hose Routing (California Model Only)
384
Evaporative Emission Control System Inspection(California Model Only)
384
Pair (Air Supply) System Diagram
385
Pair (Air Supply) System Inspection (California Model Only)
387
Hoses and Pipes
387
Pair Control/Reed Valve
387
VL1500X/Y (99,2000-Models) Contents
388
VL1500X/Y (99,2000-Models) Specifications
389
Valve/Guide Service Data
390
Camshaft/Cylinder Head Service Data
391
Front/Rear Brake Caliper
399
Fuel Level Gauge Inspection
399
Fuel Level Indicator Light and Fuel Level Meter Inspection
400
Wiring Diagram for E-02/04/17/18/22/25/34 and P-37
401
Rear Brake Hose Routing (Y-Model)
405
Canister Hose Routing
407
Evaporative Emission Control System Inspection
407
Carburetor Surge Control Valve
408
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Suzuki VL1500 Supplementary Service Manual (181 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 21.31 MB
Table of Contents
Table of Contents
2
Country and Area Codes
3
Abbreviations Used in this Manual
4
Specifications
6
Periodic Maintenance Chart
8
Periodic Maintenance Schedule
8
Fuel Hose
9
Engine Idle Speed
9
Maintenance and Tune-Up Procedures
9
Throttle Cable Play
10
Throttle Valve Synchronization
11
Exhaust Pipe Bolts and Muffler Bolts
12
Chassis Bolts and Nuts
13
Engine Components Removable with Engine in Place
14
Engine Removal and Installation
15
Engine Installation
17
Engine Disassembly and Reassembly
18
Engine Components Inspection and Servicing
19
Precautions in Servicing
20
Electrical Circuit Inspection Procedure
23
Fi System Technical Features
27
Injection Stop Control
28
Fuel Delivery System
29
Fi System Parts Location
30
Fi System Wiring Diagram
32
Ecm Terminal
33
Self-Diagnosis Function
34
Dealer Mode
35
Tps Adjustment
37
Fail-Safe Function
38
Fi System Troubleshooting
39
Visual Inspection
40
Use of Sds Diagnostic Procedures
42
Show Data When Trouble
44
Displaing Data at the Time of Dtc
44
Malfunction Code and Defective Condition
45
Fuel System
94
Fuel Pressure Inspection
95
Fuel Pump Inspection
96
Fuel Pump Relay Inspection
97
Fuel Pump Disassembly
100
Fuel Mesh Filter Inspection and Cleaning
101
Throttle Body
103
Air Cleaner Box Removal
104
Throttle Body Removal
105
Throttle Body Disassembly
106
Throttle Body Cleaning
108
Throttle Body Reassembly
109
Throttle Body Installation
111
Stp Sensor Adjustment
111
Fuel Injector Removal
112
Fuel Injector Inspection
112
Fuel Injector Installation
112
Fast Idle
113
Fast Idle Adjustment
113
Sensors
119
Ckp Sensor Inspection
120
Iat Sensor Inspection
120
To Sensor Inspection
121
Exterior Parts
122
Front Fork
123
Removal and Disassembly
124
Location of Electrical Components
128
Charging System
130
Automatic Decompression System/Starter System and Side-Stand Ignition Interlock System
132
Ignition System
134
Speedometer
139
Relays
142
Switches
143
Battery
144
Wiring Harness, Cable and Hose Routing
145
Front Brake Hose Routing
149
Rear Brake Hose Routing
150
Exterior Parts Installation
154
Brake Pedal Installation
157
Special Tools
158
Tightening Torque
159
Service Data
160
Drive Train
163
Oil Pump
163
Battery
165
Headlight
165
Spark Plug
165
Brake Light/Taillight
166
High Beam Indicator Light
166
Neutral Indicator Light
166
Oil Pressure Indicator Light
166
Position/Parking Light
166
Speedometer Light
166
Turn Signal Indicator Light
166
Tire Pressure
167
Emission Control Systems
169
Crankcase Emission Control System
170
Noise Emission Control System
172
Pair (Air Supply) System Inspection
173
Pair (Air Supply) System Diagram
175
Pair (Air Supply) System Hose Routing
176
Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)
177
Wiring Diagram
178
(German) SUZUKI VL1500 Technische Tekeningen Manual (58 pages)
Brand:
SUZUKI
| Category:
Motorcycle
| Size: 3.58 MB
Table of Contents
Battery
3
Air Cleaner
4
Alternator
5
Cam Chain
6
Cam Shaft + Valve
7
Carburetor Fittings
8
Carburetor
9
Clutch
11
Cooling Fan
12
Cosling Body Installation Parts
13
Cowling Body (Model W)
14
Crankcase Cover
15
Crankcase
16
Crankshaft
17
Electrical
18
Footrest
19
Frame Cover (Model W/X)
20
Frame
21
Front Brake Hose
22
Front Caliper
23
Front Damper
24
Front Fender
25
Front Wheel
26
Fuel Cock
27
Fuel Tank (Model W/X)
28
Gear Shifting
29
Handlebar
30
Handle Lever
31
Handle Switch
32
Cylinder Head Cover
33
Cylinder Head
34
Headlamp
35
Muffler
36
Oil Cooler
37
Oil Pan
38
Oil Pump
39
Rear Caliper
40
Rear Fender
41
Rear Master Cylinder
42
Rear Cushion Lever
43
Rear Wheel
44
Seat (Model W/X)
45
Signal Generator
46
Speedometer (Model W/X)
47
Stand
48
Starter Clutch
49
Starting Motor
50
Steering Stem
51
Rear Swinging Arm
52
Tail Lamp
53
Transmission
54
Turn Signal Lamp
55
Under Cowling
56
Wiring Harness
57
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