Lubricants

Periodic lubrication assures long life for any type of equipment. The type of lubricant used is just as important as the lubrication sendee itself, although in an emergency the wrong type of lubricant is better than none at all. The following paragraphs describe the types of lubricants most often used on motorcycle equipment. Be sure to follow the manufacturer's recommendations for lubricant types. Generally all liquid lubricants are called oil. They may be mineral-based (including petroleum...

Seals

Seals (Figure 51) are used to contain oil, water, grease or combustion gasses in a housing or shaft. Improper removal of a seal can damage the housing or shaft. Improper installation of the seal can damage the seal. Note the following a. Prying is generally the easiest and most effective method of removing a seal from a housing. However, always place a rag underneath the pry tool to prevent damage to the housing. b. Waterproof grease should be packed in the seal lips before the seal is...

Operating Requirements

An engine needs 3 basics to run properly correct fuel air mixture, compression and a spark at the right time. If one basic requirement is missing, the engine will not run. Four-stroke engine operating principles are described in Chapter Four under Engine Principles. If the bike has been sitting for any time and refuses to start, check and clean the spark plugs. If the plugs are not fouled, look to the fuel delivery system. This includes the fuel tank, fuel shutoff valve, fuel pump, in-line fuel...

Starting Notes

A sidestand switch ignition cut-off system is used on all models. The position of the sidestand will affect starting. Note the following a. The engine cannot start when the sidestand is down and the transmission is in gear. b. The engine can start when the sidestand is down and the transmission is in NEUTRAL. The engine will stop if the transmission is put into gear with the sidestand down. c. The engine can be started when the sidestand is up and the transmission is in NEUTRAL or in gear with...

Preride Inspection

The following checks should be performed prior to the first ride of the day. 1. Inspect all fuel lines and fittings for wetness. 2. Make sure the fuel tank is full of fresh gasoline. 3. Make sure the engine oil level is correct. Add oil if necessary. 4. Make sure the final drive unit oil level is correct. Add oil if necessary. 5. Check the operation of the front brake. Add hydraulic fluid to the front brake master cylinder if necessary. 6. Check the operation of the rear brake. Add hydraulic...

Brakes

The front and rear brake units are critical to riding performance and safety. Inspect the brake frequently and repair any problem immediately. When replacing or refilling the disc brake fluid, use only DOT 4 brake fluid from a closed and sealed container. See Chapter Thirteen for additional information on brake fluid selection and disc brake service. The troubleshooting procedures in Figure 16 will help you isolate the majority of disc brake troubles. When checking brake pad wear, check that...

Description

An electric starter motor is mounted horizontally in front of the front cylinder block. Figure 5 shows a schematic of the starting system and its components. The electric starting system requires a fully charged battery to provide the large amount of current required to operate the starter motor. The alternator and a voltage regulator rectifier, connected in circuit with the battery, keep the battery charged while the engine is running. The battery can also be charged externally. The starter...

Removing Broken Screws or Bolts

When the head breaks off a screw or bolt, several methods are available for removing the remaining portion. If a large portion of the remainder projects out, try gripping it with vise-grip pliers. If the projecting portion is too small, file it to fit a wrench or cut a slot in it to fit a screwdriver. See Figure 41. If the head breaks off flush, use a screw extractor. To do this, centerpunch the exact center of the remaining portion of the screw or bolt. Drill a small hole in the screw and tap...

Vs1400 Blowing Fuse After Removing Battery

Battery cables are the proper size and length. Replace cables that are undersize or damaged. c. All electrical connections are clean and tight. Especially the battery terminals. d. The wiring harness is in good condition, with no worn or frayed insulation or loose harness sockets. e. The fuel system is filled with an adequate supply of fresh gasoline. If the starter does not operate, perform the following. After completing each test, reconnect any electrical connector that was disconnected...

Zjia

Repeat for the bearing on the other side. 7. Clean the inside and the outside of the hub with solvent. Dry with compressed air. 1. On unsealed bearings, pack the bearings with a good quality bearing grease. Work the grease in between the balls thoroughly. Turn the bearing by hand a couple of times to make sure the grease is distributed evenly inside the bearing. 2. Blow any dirt or foreign matter out of the hub prior to installing the bearings. CAUTION Install unsealed bearings with the...

Preliminary Inspection

The overhaul of a starter motor is best left to an expert. This procedure shows how to detect a defective starter. Inspect the O-ring seal (A, Figure 41). O-ring seals tend to harden after prolonged use and heat and therefore lose their ability to seal properly. Replace as necessary. Inspect the starter shaft (B, Figure 41) for chipped or missing teeth. If damaged, the starter assembly must be replaced. Disassembly Refer to Figure 42 for this procedure. 1. Remove the through-bolts and washers...

Assembly

If removed, install the O-ring seal into both ends of the case. 2. Push all 4 brushes into their holders. 3. Make sure the O-ring (Figure 48) is still in place on the brush holder stud. 4. Install the threaded stud into the case, then carefully install the brush holder assembly (Figure 49) into the case. 5. Align the tab on the negative brush holder with the notch in the case (Figure 50) and push the holder down until it stops. 6. Install the insulators, washers and nut (Figure 47) securing the...

Starter Gears

Inspect the seal (Figure 58) in the left-hand end cap for wear, damage or deterioration. The seal cannot be replaced. If damaged, replace the left-hand end cap. 8. Inspect the right-hand end cap for wear or damage, replace if necessary. 9. Inspect the case assembly for wear or damage. Make sure the field coils (Figure 59) are bonded securely in place. If damaged or any field coils are loose, replace the case assembly. 10. Inspect the brush holder assembly (Figure 60) for wear or damage, if...

Testing

Remove the rider's seat and frame left-hand side cover as described in Chapter Thirteen. CAUTION When disconnecting the starter wire at the starter relay in Step 2, do not touch or ground the wrench against the other starter relay terminal. Doing so will short the terminals together. Refer to the Basic Information section at the beginning of this chapter regarding the specified test temperature of20 C (68 F). If the component is not at the specified temperature, the resulting resistance...

Bearing Installation

When installing a bearing in a housing, pressure must be applied to the outer bearing race (Figure 47). When installing a bearing on a shaft, pressure must be applied to the inner bearing race (Figure 2. When installing a bearing as described in Step 1, some type of driver will be required. Never strike the bearing directly with a hammer or the bearing will be damaged. When installing a bearing, a piece of pipe or a socket with a diameter that matches the bearing race is required. Figure 49...

Info

Install the spring stopper and tighten securely. Do not try to tighten to the correct torque at this time. 23. Install the fork assemblies as described in this chapter. If you are unable to tighten the spring stopper to the correct torque specification at this time, tighten it after the fork assembly is reinstalled in the fork bridge assembles. 24. Tighten the spring stopper to the torque specification listed in Table 1. 25. Inspect the O-ring seal on the fork cap bolt replace if necessary....

Frame Noise

Noises traced to the frame or suspension are usually caused by loose, worn or damaged parts. Various noises that are related to the frame are listed below 1. Disc brake noise A screeching sound during braking is the most common disc brake noise. Some other disc brake associated noises can be caused by d. Loose brake disc mounting bolts. e. Loose or missing brake caliper mounting bolts. g. Cracked wheel flange or bosses, where the brake disc mounts to the wheel. 2. Front fork noise Check for the...

Disassembly

Refer to Figure 12 for this procedure. 1. Remove the front wheel as described in this chapter. 2. If still in place, remove the spacer (Figure 3) from the brake disc side of the hub. 3. If still in place, remove the speedometer gear box from the left-hand side of the hub. 4. If necessary, remove the bolts securing the brake disc and remove the disc. 5. Before proceeding further, inspect the wheel bearings as described in this chapter. If they must be replaced, proceed as follows. 6A. If the...

Precision Measuring Tools

Measurement is an important part of engine and suspension service. When performing many of the service procedures in this manual, you will be required to make a number of measurements. These include basic checks such as engine compression and spark plug gap. As you expand your shop work into engine disassembly and service, measurements will be required to determine the size and condition of the piston and cylinder bore and crankshaft runout and so on. When making these measurements, the degree...

Troubleshooting

Before testing the charging system, visually check the following. 1. Check the battery connections at the battery. If polarity is reversed, check for a damaged regulator rectifier. 2. Remove the screws and the battery cover (Figure 11) and check for loose or corroded battery cable connectors. 3. Inspcct all wiring between the battery and alternator stator for worn or cracked insulation or loose connections. Replace wiring or clean and tighten connections as required. 4. Check battery condition....

Release Control System

Brushes are properly seated against the armature (Figure 51). 8. Install the washers (Figure 44) onto the end of the armature. 9. Install the left-hand end cap (A, Figure 52) and the right-hand end cap (B, Figure 52) onto the case. 10. Correctly align the case screw holes in both end caps and push the caps onto the case until they bottom out. 11. Apply a small amount of Loctite (No. 242) to the through-bolt threads prior to installation. 12. Install the through-bolts and washers (C, Figure 52)...

Engine Noises

Knocking or pinging during acceleration Can be caused by using a lower octane fuel than recommended or a poor grade of fuel. Incorrect carburetor jetting and a too hot spark plug can cause pinging. Refer to Correct Spark Plug Heat Range in Chapter Three. Check also for excessive carbon buildup in the combustion chamber or a faulty ignition system ignitor unit. 2. Slapping or rattling noises at low speed or during acceleration Can be caused by piston slap, i.e., excessive piston-cylinder wall...

Service Hints

Most of the service procedures covered are straightforward and can be performed by anyone reasonably handy with tools. However, consider your capabilities carefully before attempting any operation involving major disassembly of the engine assembly. Take your time and do the job right. Do not forget that a newly rebuilt engine must be broken-in the same way as a new one. Refer to Engine Break-In in Chapter Five. 1. Front, as used in this manual, refers to the front of the bike the front of any...

Washing The Bike

Regular cleaning of the bike is an important part of its overall maintenance. After riding your bike in extremely dirty areas, clean it thoroughly. Doing this will make maintenance and service procedures quick and easy. More important, proper cleaning will prevent dirt from falling into critical areas undetected. Failing to clean the bike or cleaning it incorrectly will add to your maintenance costs and shop time because dirty parts wear out prematurely. It's unthinkable that your bike could...

Charging Circuit

Connectors r Ground X Frame ground system problems result from an empty fuel tank, a plugged fuel filter or fuel valve, fuel pump failure or sour fuel. Fuel system troubleshooting is covered thoroughly under Engine Is Difficult To Start, Poor Idle Speed Performance and Poor Medium and High Speed Performance in this chapter. The carburetor choke system can also present problems. A choke stuck open will show up as a hard starting problem one that sticks closed will result in a flooding condition....

Charging

If recharging is required on the maintenance free battery, a digital voltmeter and a special type of charger with a built-in ammeter must be used. It is recommended that the battery be recharged by a Suzuki dealership to avoid damage to a good battery that only requires recharging. The following procedure is included if you choose to recharge this type of battery. If a battery not in use loses its charge within a week after charging, the battery is defective. A good battery should only...

Kawasaki Fork Damper Rod Tool

If any one of the following is observed replace it with a new one a. A puncture or split whose total length or diameter exceeds 6 mm (0.24 in.). b. A scratch or split on the side wall. d. Tread separation or excessive abnormal wear pattern. e. Tread depth of less than 1.6 mm (0.06 in.) in the front tire or less than 2.0 mm (0.08 in.) in the rear tire on original equipment tires. After-market tires tread depth minimum may vary. Scratches on either sealing bead. The cord is cut in any place. h....

Repairing Motorcycle Wheel Spoke Steps Pics

Build Compound Gear Box

The outer race only Do not tap on the inner race or the bearing might be damaged. Be sure that the bearings are completely seated. 3A. The Suzuki bearing installer (Suzuki part No. 09924-84510) can be used to install the wheel bearings as follows a. Install the right-hand bearing into the hub first. b. Set the bearing with the sealed side facing out and install the bearing installer as shown in Figure 14. c. Tighten the bearing installer (Figure 15) and pull the right-hand bearing into the hub...

Rotor Testing

The rotor is permanently magnetized and cannot be tested except by replacing it with a known good one. The rotor can lose magnetism from old age or a sharp hit. If defective, the rotor must be replaced it cannot be remagnetized. Refer to the Basic Information section at the beginning of this chapter regarding the specified test temperature of 20 C (68 F). If the component is not at the specified temperature, the resulting resistance readings will be inaccurate.

Electrical Connectors

The 1400 Intruder is equipped with many electrical components, connectors and wires. Corrosion-causing moisture can enter these electrical connectors and cause poor electrical connections leading to component failure. Troubleshooting an electrical circuit with one or more corroded electrical connectors can be time consuming and frustrating. When reconnecting electrical connectors, pack them with a dielectric grease compound. Dielectric grease is especially formulated for sealing and...

Electrical Connection Location

The location of clectrical connectors varies with the different years. Also, if the bike has been worked on by someone else, they may have positioned the connector differently than the factory location. The photographs shown in this chapter are based on the 1997 VS1400 Intruder model, but electrical connector location on the bike you are working on may vary. Always check the connectors wire colors called out in the procedures to make sure you are working with the correct electrical connector....

California Only

Hose (canister valve joint) Refer to Figure 68 for the following procedure. 1. Loosen the clamping bolt where both mufflers attach at the common connector just forward of the rear wheel. 2. Loosen the clamping bolt (Figure 69) where the exhaust pipe connects to the muffler. 3. Remove the bolt, washer and nut (Figure 70) securing the muffler to the frame mounting bracket. 4. Disengage the muffler from the common connector of the other muffler, then remove the muffler. 5. Repeat Steps 3 and 4...

Exhaust System

The exhaust system is a vital performance component. Check the exhaust system for deep dents and fractures and repair or replace them immediately. Check the muffler frame mounting flanges for fractures and loose bolts. Check the cylinder head mounting flanges for tightness. A loose exhaust pipe connection can cause a decrease in engine performance.

Removal Installation Main Valve

Some fuel may spill in the following procedure. Work in a well-ventilated area at least 50 ft. (15 m) from any sparks or flames, including gas appliance pilot lights. Do not allow anyone to smoke in the area. Keep a BC rated fire extinguisher handy. 1. Remove the rider's seat as described in Chapter Thirteen. 2. Remove the bolt securing the frame left-hand side cover and remove the cover. 3. Remove the fuel tank and drain it of all fuel as described in this chapter. 4. Disconnect the single...

O

Inspect the front mounting bracket for cracks or damage. If necessary, remove the bolts on each side and remove the bracket. 15. Check the rear mounting bracket, collars and rubber cushions (Figure 62) for wear or damage. 16. Install by reversing these removal steps, noting the following a. Refill the fuel tank if it was drained. b. Make sure the rubber cushion is in place in the frame mounting bracket. c. Be sure to reconnect the fuel hoses onto the correct fittings. d. Turn the fuel tank...

Removal Installation

Remove each carburetor and its throttle cable as an assembled unit. Leaving the cables attached to both will save time during the installation procedure and make the synchronization procedure a lot easier. 1. Remove both seats as described in Chapter Thirteen. 2. Remove the fuel tank as described in this chapter. 3. Remove both frame head side covers (A, Figure 1) as described in Chapter Thirteen. 4. Disconnect the battery negative lead as described in Chapter Nine. 5. Remove the bolts securing...

Carburetor Operation

For proper operation, a gasoline engine must be supplied with fuel and air mixed in proper proportions by weight. A mixture in which there is an excess of fuel is said to be rich. A lean mixture is one which contains insufficient fuel. A properly adjusted carburetor supplies the proper mixture to the engine under all operating conditions. Each carburetor consists of several major systems. A float and float valve mechanism maintains a constant fuel level in the float bowl. The pilot system...

Suzuki Vs 1400 How Long Spring Clutch

Refer to Figure 45 for this procedure. 1. Install the inner washer (A, Figure 68) and outer washer (B, Figure 68) onto the transmission shaft. 2. Install the bushing (B, Figure 53) onto the transmission shaft. 3. Apply a good coat of clean engine oil to the needle bearing and install the needle bearing (A, Figure 53). 4. Align the notch (A, Figure 69) in the oil pump drive gear with the locating pin (B, Figure 69) and install it onto the backside of the outer housing. Make sure the gear is...

Locknut Nut Clutch Honda Wave

Suzuki Intruder Cam Install

Remove the cam gear slowly as the small pawls, pins and springs are loose and will fall out during removal. 11. Slowly remove the cam gear assembly (Figure 7) from the stopper plate. As soon as the pawls start to clear the stopper plate hold them in place with your fingers to avoid loosing the small parts. Place the assembly into the small cap from an aerosol spray container (Figure 8) then place into a recusable plastic bag to avoid misplacing any small parts. 12. Remove the stopper plate...

Removal

Refer to Figure 1 for this procedure. 1. Remove the exhaust system as described in Chapter Eight. 2. Remove the front footpeg assembly as described in Chapter Thirteen. 3. Remove the clutch slave cylinder as described in this chapter. 4. Remove the neutral switch, plunger and spring as described in Chapter Nine. A gasket washer is located under the lower 3 holts. These gasket washers must be reinstalled on the same three bolts to prevent an oil leak. 5. Remove the bolts securing the external...

Clutch And External Shift Mechanism

This chaptcr provides complete service procedures for the clutch, the clutch release mechanism and the external shift mechanism. The clutch is a wet multi-plate type which operates immersed in the engine oil. It is mounted on the right-hand end of the transmission mainshaft. The inner clutch hub is splined to the mainshaft and the outer housing can rotate freely on the mainshaft. The outer housing is geared to the crankshaft. The clutch pushrods ride within the channel in the transmission...

Gasket Sealer Secondary Case

If removed, install the case locating dowels (Figure 39) in the crankcase. Use ThreeBond No. J104, or equivalent gasket sealer to seal the secondary case. When selecting an equivalent, avoid thick and hard-setting materials. CAUTION Do not apply gasket sealer to the oil jet cavity in the cover (A, Figure 40). If sealer gets into the cavity the oil flow to the assembly will be reduced or completely blocked. 18. Apply a light coat of gasket sealer to the secondary case sealing surfaces on the...

Inspection

Check both hoses for damage or leakage, rcplace if necessary. 2. Inspcct the rubber grommets at each mounting point for hardness or deterioration. Replace as necessary. 3. Inspect the cooler fins (Figure 8) for damage. Straighten out bent fins with a broad tipped screwdriver or putty knife. 4. If compressed air is available, use short spurts of air directed to the backside of the coolcr fins to blow out any road dirt and bugs. 5. If the cooler fins are extremely dirty, flush off the exterior of...

Vs1400 Swing Trim Panel

Intake valve closes and piston rises in cylinder, A compressing air fuel mixture. Intake valve opens as piston begins downward, drawing air fuel mixture into the cylinder, through the valve. Spark plug ignites compressed mixture, driving piston downward Force is applied to crankshaft Exhaust valve opens as piston rises in cylinder, pushing spent gases out through the valve. help hold the engine while you loosen many of the larger nuts and bolts. The following components can be serviced while...

Warning

With the engine idling, move the handlebar from side to side. If the idle speed increases during this movement, the throttle cable may need adjusting or may be incorrectly routed through the frame. Correct this problem immediately. Do not ride the bike in this unsafe condition. 12. Test ride the bike, slowly at first, and make sure the throttle cables are operating correctly. Readjust if necessary. Automatic Compression Release Cable Free Play Check and Adjustment Check the free play automatic...

Note

Suzuki does not designate what degree range constitute summer or winter temperatures. They do specify that the engine oil temperature should be at 60 C (140 F). 5A. In summer temperatures start the engine and allow to idle for 10 minutes at 2,000 rpm. 5B. In winter temperatures start the engine and allow to idle for 20 minutes at 2,000 rpm. 6. After the engine has warmed up for the specified time period, increase the engine speed to 3,000 rpm and note the gauge reading. Refer to the specified...

Carburetor Service

Carburetor disassembly and assembly is separated into 3 different procedures. The piston valve assembly and coasting valve are basically the same on both the front and rear carburetors and are covered in one procedure. The components in the float chamber area, floats and jets, vary considerably between the front and rear carburetors and are covered separately to avoid confusion. Piston Valve Assembly and Coasting Valve Refer to the following illustrations for this procedure Disassemble only one...

Ignition System

All models are equipped with a transistorized ignition system. This solid state system uses no contact breaker point or other moving parts. Figure 12 shows a schematic of the ignition system and its components. Because of the solid state design, problems with the transistorized system are rare. If a problem occurs, it generally causes a weak spark or no spark at all. An ignition system with a weak spark or no spark is relatively easy to troubleshoot. It is difficult, however, to troubleshoot an...

Service Intervals

The services and intervals shown in Table 1 are recommended by the factory. Strict adherence to these recommendations will ensure long service from the Suzuki. If the bike is run in an area of high humidity, perform the lubrication services more frequently to prevent rust damage. For convenience when maintaining your motorcycle, most of the sendees shown in these tables are described in this chapter. However, some procedures which require more than minor disassembly or adjustment are covered...

Tire Pressure

Tire pressure must be checked and adjusted to maintain the tire profile, good traction and handling and to get the maximum life out of the tire. A simple, accurate gauge can be purchased for a few dollars and should be carried in your motorcycle tool kit. Tire pressure must be checked when the tires are cold. The appropriate tire pressures are shown in Table 2. After checking and adjusting the air pressure, install the air valve cap. The cap prevents small pebbles and dirt from collecting in...

Notes Cautions And Warnings

The terms NOTE, CAUTION and WARNING have specific meanings in this manual. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience, but would not cause equipment damage or personal injury. A CAUTION emphasizes areas where equipment damage could result. Disregarding a CAUTION could cause permanent mechanical damage however, personal injury is unlikely. A WARNING emphasizes areas where personal injury or even death could...

Starting a Flooded Engine

If the engine will not start and there is a strong gasoline smell, the engine may be flooded. If so, open the throttle all the way and operate the starter. Do not open the choke. Holding the throttle open allows more air to reach the engine. If the engine refuses to start, check the carburetor overflow hose attached to the fitting at the bottom of each float bowl If fuel runs out the end of one or both hoses, the float is stuck open, allowing the carburetor to overfill If this problem exists,...

Fuel System

Many riders automatically assume that the carburetors are at fault when the engine does not run properly. While fuel system problems are not uncommon, carburetor adjustment is seldom the answer. In many cases, adjusting the carburetors only compounds the problem by making the engine run worse. Fuel system troubleshooting should start at the fuel tank and work through the system, reserving the carburetor assembly as the final point. Most fuel

Tire Wear Analysis

Abnormal tire wear should be analyzed to determine its causes. The most common causes are the following a. Incorrect tire pressure Check tire pressure as described in this chapter. c. Incorrect wheel balance The tire wheel assembly should be balanced when installing a new tire and or tube and then re-balanced each time the tire is removed and reinstalled. d. Worn or damaged wheel bearings. Incorrect tire pressure is the biggest cause of abnormal tire wear. Under-inflated tires will result in...

Electrical Systems

This chapter contains operating principles, service procedures and test procedures for all electrical system components. Information regarding the battery and spark plugs are covered in Chapter Three. The electrical system includes the following systems g. Various electrical components. Tables 1-3 are located at the end of this chapter. Where differences occur relating to the United Kingdom U.K. models they are identified. If there is no U.K. designation relating to a procedure, photo or...

Mile Service

It is essential that the oil and filter be changed after the first 500 miles. In addition, it is a good idea to change the oil and filter at the completion of break-in about 1,500 miles to ensure that all of the particles produced during break-in are removed from the lubrication system. The small added expense may be considered a smart investment that will pay off in increased engine life. Table 1 ENGINE LOWER END SERVICE SPECIFICATIONS Table 1 ENGINE LOWER END SERVICE SPECIFICATIONS Table 2...

Battery Electrical Cable Connectors

To ensure good electrical contact between the battery and the electrical cables, the cables must be clean and free of corrosion. 1. If the electrical cable terminals are badly corroded, disconnect them from the bike's electrical system. 2. Thoroughly clean each connector with a wire brush and then with a baking soda solution. Rinse thoroughly with clean water and wipe dry with a clean cloth. 3. After cleaning, apply a thin layer of dielectric grease to the batter ' terminals before reattaching...

Torque Specifications

The materials used in the manufacture of your Suzuki may be subjected to uneven stresses if the fasteners used to hold the sub-assemblies are not installed and tightened correctly. Improper bolt tightening can cause cylinder head warpage, crank-case leaks, premature bearing and seal failure and suspension failure. An accurate torque wrench described in this chapter should be used together with the torque specifications listed at the end of most chapters. Torque specifications throughout this...

Engine Overheating

Engine overheating is a serious problem in that it can quickly cause engine seizure and damage. The following section groups 5 main systems with probable causes that can lead to engine overheating. b. Incorrect spark plug heat range see Chapter Three. c. Faulty ignitor unit incorrect ignition timing. a. Cylinder head gasket leakage. b. Heavy carbon buildup in combustion chamber. e. Plugged oil cooler and or oil cooler lines. f. Oil not circulating properly. a. Clogged air filter element s . b....

Suzuki Vs1400 Intruder Rider Comfort

Remove the rider's seat and the frame side covers as described in Chapter Thirteen. 2A. On 1987-1995 models, disconnect the two regulator rectifier unit electrical connectors Figure 7 as follows a. Locate the alternator's 3-pin electrical connector containing 3 yellow wires and disconnect the connector. b. Locate the alternator's 5-pin electrical connector containing 5 wires 1 orange, 2 red, 2 black white and disconnect the connector. c. Set the pocket tester to the R x 1,000 K ohms scale....

Fuel Pump Resistance Check

Refer to the Basic Information section at the beginning of this chapter regarding the specified test temperature of 20 C 68 F . If the component is not at the specified temperature, the resulting resistance readings will be inaccurate. 1. Remove the rider's seat as described in Chapter Thirteen. 2. Disconnect the battery negative lead as described in this chapter. 3. Remove the bolts securing the frame left-hand side cover and remove the cover. 4. From the fuel pump, follow the electrical...

Starter Motor

May be worn to the same level Figure 55 . If necessary, have the commutator serviced by a dealership or electrical repair shop. 3. Inspect the commutator copper bars for discoloration. If a pair of bars are discolorcd, grounded armature coils are indicated. 4. Use an ohmmeter and perform the following a. Check for continuity between the commutator bars Figure 56 there should be continuity between any 2 of the bars. b. Check for continuity between the commutator bars and the shaft Figure 57...

Serial Numbers

Suzuki makes frequent changes during a model year, some minor, some relatively major. When you order parts from the dealer or other parts distributor, always order by VIN and engine serial numbers. The frame serial number is stamped on the right-hand side of the steering head. The engine number is stamped on a raised pad on the left-hand side rear comer of the crankcase Figure 13 . The frame or VIN serial number is stamped on the right-hand side of the steering stem Figure 14 . The carburetor...

Clutch Hydraulic System

The clutch is actuated by hydraulic fluid pressure and is controlled by the hand lever on the clutch master cylinder located on the left-hand handlebar. As clutch components wear, the fluid level in the reservoir will be lower as it automatically adjusts for wear. There is no routine adjustment necessary nor possible. When working on the clutch hydraulic system, it is necessary that the work area and all tools be absolutely clean. Any tiny particles or foreign matter and grit in the clutch...

Clutch Fluid Level Check

The clutch is hydraulically operated and requires no routine adjustment. The hydraulic fluid in the clutch master cylinder should be checked as listed in Table 1 or whenever the level drops, whichever comes first. Bleeding the clutch system and servicing clutch components are covered in Chapter Six. CAUTION If the clutch operates correctly when the engine is cold or in cool weather, but operates erratically or not at all after the engine warms-up or when riding in hot weather, there is air in...

General Tips

Read your owner's manual regarding safety information and instructions and know your machine. 2. Check the throttle and brake controls before starting the engine. 3. Know how to make an emergency stop. 4. Never add fuel while anyone is smoking in the area or when the engine is running. 5. Never wear loose scarves, belts or boot laces that could catch on moving parts. 6. Always wear eye protection, head protection and protective clothing to protect your entire body. 7. Riding in the winter...

Transmission 5speed 1997on

Countershaft 3rd gear 23 Countershaft 3rd gear 27. Countershaft 4th gear bushing 7. Align the oil hole in the fifth gear bushing A, Figure 9 with the transmission shaft oil hole B, Figure 9 and slide on the bushing. This alignment is necessary for proper gear lubrication. 8. Slide the fifth gear Figure 10 onto the bushing. Perform Steps 9-17 by installing the parts from the mainshaft's right-hand side. 9. Align the oil hole in the second gear bushing A, Figure 11 with the transmission shaft...

Standard Inch Micrometer

The vernier scale consists of eleven equally spaced lines marked 0-9 with a 0 on each end. These lines run parallel on the top of the sleeve where each line is equal to 0.0001 inch. Thus, the vernier scale divides a thousandth of an inch 0.001 in. into ten-thousandths of an inch 0.0001 in. To read the vernier micrometer, perform the following steps and refer to the example in Figure 31. 1. Read the micrometer in the same way as on the standard inch micrometer. This is the...

Lubrication Maintenance And Tuneup

A motorcycle, even in normal use, is subjected to tremendous heat, stress and vibration. When neglected, any bike becomes unreliable and actually dangerous to ride. To gain the utmost in safety, performance and useful life from the Suzuki Intruder, it is necessary to make periodic inspections and adjustments. Frequently minor problems are found during these inspections that are simple and inexpensive to correct at the time. If they are not found and corrected at this time they could lead to...

Starting Difficulties

Intruder Vs800 Clutch Isues

If the engine turns over but is difficult to start, or will not start at all, it does not help to run down the battery with the electric starter. Check for obvious problems even before getting out your tools. Go down the following list step-by-step. Do each one while remembering the 3 engine operating requirements described under Operating Requirements earlier in this chapter. If the engine still will not start, refer to the appropriate troubleshooting procedures that follow in this chapter. 1....

Engine Upper

The engine is a V-twin air oil-cooled, 4-stroke design. The cylinders arc offset and set at a 45 angle. The cylinders fire on alternate crankshaft rotations. Each cylinder is equipped with a single camshaft and 4 valves. The crankshaft is supported by 2 main bearings in a vertically split crankcase. Both engine and transmission share a common case and the same wet sump oil supply. The clutch is a wet-type located inside the right crankcase cover. Refer to Chapter Six for clutch and external...

Taillightbrake Light And License Plate Light

License plate light housing License Plate Light Bulb Replacement Refer to Figure 98 for this procedure. 1. Remove the screws securing the cover B, Figure 99 and remove the cover. 2. Remove the lens A, Figure 100 from the housing on the license plate bracket. 3. Wash out the inside and outside of the lens with a mild detergent and wipe dry. 4. Inspect the lens gasket B, Figure 100 and replace if damaged. 5. Push in and turn the bulb C, Figure 100 counterclockwise to remove it. 6. If removed,...

Difficult Shifting

If the shift shaft does not move smoothly from one gear to the next, check the following. a. Incorrectly installed shift lever. b. Stripped shift lever-to-shift shaft splines. d. Damaged shift shaft return spring. e. Damaged shift shaft where it engages the shift drum. f. Loosen shift return spring pin. g. Shift drum positioning lever binding on pivot bolt. a. Seized or damaged stopper lever roller. b. Broken stopper lever spring. c. Loose stopper lever mounting bolt. b. Damaged shift fork...

Starting a Cold Engine

Shift the transmission into NEUTRAL. 2. Turn the fuel shutoff valve to the ON position. 3. Move the ENGINE STOP switch to the RUN position. 4. Turn the ignition switch to the ON position. 5. Turn the choke lever all the way clockwise to the full ON position. 6. With the throttle completely closed, push the START button. 7. When the engine starts, work the throttle slightly to keep it running. 8. Idle the engine approximately for a minute or until the throttle responds cleanly, then turn the...

Poor Idle Speed Performance

If the engine starts but off-idle performance is poor engine hesitation, cutting out, etc. , check the following 1. Clogged or damaged air filter s . d. Incorrect throttle cable adjustment. e. Incorrect carburetor adjustment. f. Flooded carburetor visually check carburetor overflow hose for fuel . g. Vacuum piston doesn't slide smoothly in carburetor bore. a. Water and or alcohol in fuel. c. Damaged signal generator rotor and or signal generator.

ISO Metric Screw Threads Bolts Nuts and Screws

Iso Metric Screw

ISO International Organization for Standardization metric threads come in 3 standard thread sizes coarse, fine and constant pitch. The ISO coarse pitch is used for almost all common fastener applications. The fine pitch thread is used on certain precision tools and instruments. The constant pitch thread is used mainly on machine parts and not for fasteners. The constant pitch thread, however, is used on all metric thread spark plugs. Metric fasteners are classified by length L, Figure 4 ,...

Engine Leakdown Test

An engine leakdown test can isolate engine problems caused by leaking valves, blown head gaskets or broken, worn or stuck piston rings. A cylinder leakage test is performed by applying compressed air to the cylinder and then measuring the percent of leakage. A cylinder leakage tester Figure 14 and an air compressor are required to perform this test. Follow the manufacturer's directions along with the following information when performing a cylinder leakdown test. 1. Start and run the engine...

Chapter Thirteen

BODY AND Frame head side covers Front fender CARBURETOR SERIAL NUMBER OR I.D. MARK _ ____________ 87 R M 2 method or 91 octane or higher ENGINE, FORK OIL, FINAL DRIVE UNIT REFILL CAPACITIES ENGINE, FORK OIL, FINAL DRIVE UNIT REFILL CAPACITIES 3.7 L 3.9 U.S. qts. or 3.2 Imp. qts. 4.3 L 4.5 U.S. qts. or 3.8 Imp. qts. 200-220 ml 6.8-7.4 U.S. oz. or 7.0-7.7 Imp oz. Front fork oil capacity each fork leg 354 ml 12.0 U.S. oz. or 12.5 Imp. oz. MAINTENANCE AND TUNE-UP SPECIFICATIONS Automatic...

Starting The Engine

When your engine refuses to start, frustration can cause you to forget basic starting principles and procedures. The following outline will guide you through basic starting procedures. In all cases, make sure that there is an adequate supply of fuel in the tank. If you have been working on the bike and have removed the seat s , be sure to reinstall the rider's seat prior to starting the engine. The ignition system's ignitor unit is attached to the underside of the rider's seat and the...

Disc Brake Troubleshooting

Loose or damaged line fittings Scored caliper piston or bore Leaking master cylinder diaphragm Leaking master cylinder secondary seal Cracked master cylinder housing Caliper piston and or brake pads hanging up Loose front axle nut and or clamps Plugged passages in master cylinder Caliper piston and or brake pads hanging up Leaking primary cup seal in master cylinder Contaminated brake pads and or disc Contaminated brake pads and or disc Dust or dirt collected behind brake pads d. Loose or...

Lights and Horn

With the engine running, check the following. 1. Pull the front brake lever on and check that the brake light comes on. 2. Push the rear brake pedal down and make sure the brake light comes on soon after you depresse the pedal. 3. With the engine running, check to see that the headlight and taillight are on. 4. Move the dimmer switch up and down between the HI and LO positions and check to see that the headlight elements are working in the headlight s . 5. Push the turn signal switch to the...

Electrical Components

Suzuki Intruder Battery Wiring

This section contains information on electrical components other than switches. Some of the test procedures covered in this section instruct taking a meter reading within the electrical connector while it is still attached to a specific part. Under these conditions make sure that the meter test lead has penetrated the connector and is touching the bare metal wire not the insulation on the wire. If the test lead does not touch the bare metal wire the reading will be false and may lead to the...

Install A Strator On Vs1400

1400 Intruder Anlasser Position

Remove the alternator stator assembly as described in this chapter. 2. Remove the collar Figure 62 from the starter drive gear shaft. 3. Remove the drive gear shaft A, Figure 63 and drive gear B, Figure 63 . 4. Remove the idle gear shaft A, Figure 64 and idle gear B, Figure 64 . 5. Remove the alternator rotor as described in this chapter. 6. Remove the Woodruff key A, Figure 65 from the crankshaft and place it on the inner magnetic surface of the rotor. 7. Remove the starter clutch gear B,...

Starting And Automatic Compression Release Control System

Install the fuel tank as described in Chapter Eight. Compression Release Solenoid Removal Installation 1. Remove the fuel tank as described in Chapter Eight. 2. Remove the frame left-hand side cover as described in Chapter Thirteen. 3. Remove the No. 1 rear cylinder's ignition coil as described in this chapter. The No. 1 coil is mounted at the front of the two coils. 4. Remove the rear air filter case and rear carburetor as described in Chapter Eight. 5. Remove the intake pipe from the rear...

Clutch Master Cylinder

Wash hydraulic fluid from any painted or plated surfaces or plastic parts immediately as it will destroy the finish. Use soapy water and rinse completely. 1. Disconnect the electrical connector Figure 91 from the clutch interlock switch. 2. Unscrew and remove the rear view mirror A, Figure 92 . 3. Remove the screws, washers and lock washers securing the clutch interlock switch Figure 93 and remove the switch. 4. Remove the scrcws and remove the reservoir cover...

Ignitor Unit Test

Remove the frame left-hand side cover as described in Chapter Thirteen. 3. Disconnect the vacuum hose A, Figure 34 from the boost sensor. 4. Disconnect the electrical connector B, Figure 34 from the boost sensor. 5. Remove the nuts securing the boost sensor C, Figure 34 to the mounting bracket and remove the sensor from the frame. 6. If necessary, disconnect the boot sensor hose from the fitting on the front cylinder intake port. Carefully remove the hose from the frame, noting its path...

Vernier Caliper Dial Caliper and Digital Electronic Caliper

These tools read inside, outside and depth measurements. The vernier caliper is shown in Figure 25. Although this type of tool is not as precise as a micrometer, they allow reasonably accurate measurements, typically to within 0.025 mm 0.001 in. . Common uses of a vernier caliper are measuring the length of the clutch springs, the thickness of clutch plates, shims and thrust washers, brake pad or lining thickness or the depth of a bearing bore. The jaws of the caliper must be clean and free of...

Tread Depth

Check local traffic regulations concerning minimum tread depth. Measure the tread depth at the center of tire and to the center of the tire tread Figure 1 using a tread depth gauge or a small ruler. Suzuki recommends to replace original equipment tires when the front tire tread depth is 1.6 mm 1 16 in. or less, when the rear tread depth is 2.0 mm 3 32 in. or less, or when tread wear indicators appear at the designated area on the tire indicating the minimum tread depth. Frequently inspect wheel...

Final Drive Oil Change

The factory-recommended oil change interval is listed in Table 1. To drain the oil you will need the following c. Approximately 200-220 ml 6.8-7.4 U.S. oz. 6.7-7.4 Imp. oz. of hypoid gear oil. Discard old oil as outlined under Engine Oil and Filter Change in this chapter. 1. Ride the bike until normal operating temperature is obtained. Usually 15-20 minutes of stop-and-go riding is sufficient. 2. Place the bike on the centerstand. 3. Place a drain pan under the drain plug. 4. Remove the oil...

Removal Installation Sub Valve

Some fuel may spill in the following procedure. Work in a well-ventilated area at least 50 ft. 15 m from any sparks or flames, including gas appliance pilot lights. Do not allow anyone to smoke in the area. Keep a BC rated fire extinguisher handy. 1. Remove the fuel tank and drain it of all fuel as described in this chapter. 2. Place some cardboard on the workbench to protect the surface of the fuel tank. 3. Turn the fuel tank on its side with the fuel shutoff valve side up. 4. Remove the bolts...

Rear Carburetor Assembly

Suzuki Intruder Fuel Lines

The way down and install the screws and any hose clamps in the correct location. 11. Tighten the scrcws A, Figure 13 securely. and Carburetor Body Disassembly Assembly Refer to Figure 11 for this procedure. 1. Remove the screws securing the float bowl and remove the float bowl and O-ring seal. 2. Push the float pin A, Figure 24 out of the mounting boss and remove it. 3. Remove the float B, Figure 24 and needle valve assembly. 4. Remove the screw A, Figure 25 securing the needle valve seat and...

Installation

1400 Suzuki Intruder Spark Plug Removal

CAUTION Whenever the cylinder head cover is removed, the hydraulic tappets located within the rocker arms must be bled of any air that may have entered during the cover removal procedure. Failure to do so will result in a loud clicking noise and may result in engine damage. 1. Remove all 3 tappets from the rocker arms and bleed each one as described in this chapter. Reinstall the tappets into the rocker arms. 2. Check the timing mark for the rear cylinder. The RT mark on the alternator rotor A,...

Suzuki Intruder 1400 Crank Shaft Bolt Removal

Remove the clutch assembly as described in Chapter Six. 2. Remove the engine from the frame as described in Chapter Four. 3. Install a clutch holding tool, or equivalent, A, Figure 9 onto the gear to hold it secure while loosening the mounting bolt. CAUTION The primary drive gear holt has left-hand threads. Turn the holt clockwise to loosen it. 4. Use a breaker bar and socket B, Figure 9 and loosen the bolt in a clockwise direction. 5. Remove the shoulder bolt A, Figure 10 and the primary...

Screwdrivers

Intruder Fly Box

The screwdriver is a very basic tool, but if used improperly, it will do more damage than good. The slot on a screw has a definite dimension and shape. A screwdriver must be selected to conform with that shape. Use a small screwdriver for small screws and a large one for large screws or the screw head will be damaged. Two basic types of screwdriver are required common flat-blade screwdrivers and Phillips screwdrivers. Screwdrivers are available in sets which often include an assortment of...

Valve Removal

Suzuki Intruder 1400 Head Removal

Remove the cylinder head as described in this chapter. CAUTION To. avoid loss of spring tension, do not compress the springs any more than necessary to remove the keepers. 2. Compress the valve springs with a valve spring-compressor Figure 107 . Remove the valve keepers, release the compressor and remove it. 3. Remove the valve spring retainer and valve springs. 4. Prior to removing the valve, remove any burrs from the valve stem Figure 108 . Otherwise the valve guide will be damaged. 6....

Clutch Assembly

Hold the clutch center and slide the spacer A, Figure 50 off the transmission shaft. 19. Remove the clutch ccnter B, Figure 50 . 20. Remove the washer A, Figure 51 . 21. Carefully remove the outer housing B, Figure 51 . Be careful not to drop the oil pump driven gear A, Figure 52 and locating pin B, Figure 52 located on the backside of the outer housing. 22. Remove the needle bearing A, Figure 53 , bushing B, Figure 53 , outer washer A, Figure 54 and inner washer B, Figure 54 from the...

Throttle Cable Replacement

Suzuki 500e Throttle Cable Routing

This procedure describes the replacement of the throttle cable from the throttle grip to the throttle cablc connector at the carburetor assembly. Replacement of the throttle cables attached to both carburetors is covered under Carburetor Separation in this chapter. 1. Remove the seats as described in Chapter Thirteen. 2. Remove the fuel tank as described in this chapter. 3. Disconnect the battery negative lead as described in Chapter Nine. 4. Loosen the throttle cablc locknut A, Figure 54 at...

Intruder 1400 Clutch Bolt Spacer

CAUTION Cover the fuel tank, front fender and instrument cluster with a heavy cloth or plastic tarp to protect them from accidental hydraulic fluid spills. Wash hydraulic fluid from any painted or plated surfaces or plastic parts immediately as it will destroy the finish. Use soapy water and rinse completely. 1. Remove the bolts securing the secondary drive cover Figure 109 and remove the cover and bolt spacers. 2. Remove the cap and attach a hose to the bleed valve Figure 110 on the slave...

Charcoal Canister Removal Installation

Remove the rider's seat as described in Chapter Thirteen. 2. Disconnect the battery negative lead as described in Chapter Nine. 3. Remove the screw and cover from both ends of the canister. 4. Remove the bolts securing the frame right-hand side cover and remove the cover. 5. Remove the bolt and washer A, Figure 67 securing the charcoal canister to the crankcase. Prior to removing the hoses from the purge control valve and the charcoal canister, mark each hose and fitting with a piece of...

Fuel Tank Removal Installation

Tank Mounting Rubbers Intruder

Refer to Figure 58 for this procedure. 1. Remove the rider's seat as described in Chapter Thirteen. 2. Disconnect the battery negative lead as described in Chapter Nine. WARNING Some fuel may spill in the following procedure. Work in a well-ventilated area at least 50 ft. 15 m from any sparks or flames, including gas appliance pilot lights. Do not allow anyone to smoke in the area. Keep a BC rated fire extinguisher handy. 3. Turn the main fuel shutoff valve to the OFF position A, Figure 59 ....