Bearing Installation

When installing a bearing in a housing, pressure must be applied to the outer bearing race (Figure 68). 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 an outer diameter that matches Figure 71, the balls will push...

Bleeding The System

This procedure is not necessary unless the brakes feel spongy, there has been a leak in the system, a component has been replaced or the brake fluid has been replaced. 1. Remove the dust cap from the bleed valve (Figure 70) on the caliper assembly. 2. Connect a piece of clear tubing to the bleed valve on the caliper assembly. CAUTION Cover the wheel with a heavy cloth or plastic tarp to protect it from the accidental spilling of brake fluid. Wash any brake fluid off of any plastic, painted or...

Note

A cylinder at TDC will have free play in both sets of intake and exhaust valve rocker arms indicating that all of the valves are closed. 7. Use a socket and wrench on the alternator rotor bolt. Rotate the engine clockwise, as viewed from the left-hand side, until the rear cylinder is at top dead center (TDC) on the compression stroke. Align the R F T mark with the center of the inspection ho e in the a tematoT rotor (Figure 105). 8. With the R F T mark aligned with the center of the inspection...

Info

Bike while you work on the right-hand side along with the meter while having access to the throttle grip. This will lessen the possibility of getting burned on one of the HOT mufflers. 1. Start the engine and let it reach normal operating temperature. Shut off the engine. 2. Connect a portable tachometer following the manufacturer's instructions. 3. Remove the screw (A, Figure 3) securing the battery positive (+) cable terminal protector, remove the protector (B, Figure 3). 4. Restart the...

Front Wire Wheel

Spacer 9. Distance collar 4. Brake disc 11. Speedometer gear 6. Inner tube 13. Trim cap ight- and left-hand bearings and rt a soft aluminum or brass drift hub. collar over to one side and place r race of the lower bearing, out of the hub with a hammer, perimeter of the inner race, aring on the other side, and the outside of the hub with mpressed air. arings, pack the bearings with lg grease. Work the grease in )roughly turn the bearing by es to make sure the...

Front

Inspect each wheel bearing prior to removing it from the wheel hub. CAUTION Do not remove the wheel bearings for inspection purposes as they will be damaged during the removal process. Remove wheel bearings only if they are to be replaced. 1. Perform Steps 1 -4 of Disassembly in the following procedure. 2. Turn each bearing by hand. Make sure bearings turn smoothly. 3. Inspect the play of the inner race (Figure 14) of each wheel bearing. Check for excessive axial play (A, Figure 15) and radial...

Water Pump

Refer to Figure 22 for this procedure. 1. Drain the cooling system as described under Coolant Change in Chapter Three. 2. Remove the bolts (A, Figure 16) and acorn nut (B, Figure 16) securing the water pump trim cover and remove the trim cover. 3. Loosen the clamping screw on the water pump inlet hose clamps. Move the clamps back onto the hose and off of the neck of the fitting on the frame rail and water pump connector. Remove the hose (A, Figure 17) from both fittings.

Radiator

Refer to Figure 3 for this procedure. 1. Drain the cooling system as described u Coolant Change in Chapter Three. 2. Remove the seat as described in Chapter teen. 3. Disconnect the battery negative lead as descri under Battery in Chapter Three. 4. Remove the fuel tank as described under I Tank Removal Installation in Chapter Seven. 5. Remove the screws securing both the right-left-hand frame head side covers. Remove both s covers. 6. Remove the screws securing the radiator cot (Figure 4) and...

Oil Pump

The oil pump can be removed with the engine mounted in the frame this procedure is shown with the engine removed for clarity. 1. Remove the clutch assembly as described in Chapter Five. During clutch removal, the oil pump driven gear was removed. 2. Remove the bolts (A, Figure 202) securing the oil pump to the crankcase and remove the oil pump assembly.

Frame

The frame does not require routine maintenance. However, it should be inspected immediately after any accident or spill. 1. Remove the seats, frame head side covers, frame side covers and fuel tank. 2. Remove the engine as described in Chapter Four. 3. Remove the front wheel, steering stem and front forks as described in Chapter Ten. 4. Remove the speedometer and headlight case as described in Chapter Eight. 5. Remove the rear wheel, shock absorber and swing arm as described in Chapter Eleven....

Front Cast Wheel

Blow any dirt or foreign matter out of the hub prior to installing the bearings. CAUTION Install non-sealed bearings with the single sealed side facing outward. Tap the bearings squarely into place and tap on 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. A special Suzuki tool set-up (Suzuki part No. 09924-84510) can be used to install the wheel bearings as follows a. Install the right-hand bearing into the...

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...

Ter Gears

If still installed on the crankshaft, remove the starter driven gear from the crankshaft. 6. If removed, install the starter driven gear into the backside of the alternator rotor. 7. Try to rotate the starter driven gear (Figure 80). It should rotate freely in one direction and be locked up in the other direction. 8. If the starter driven gear will rotate in both directions or is locked up in both directions, replace the starter clutch as described in this chapter. 1. Inspect the starter idler...

Chapter Eight

Starter interlock switch (Clutch switch) terlock switch (1987-on models), starter relay, battery and starter motor as shown in Figure 33. Each component of this system is covered separately in this chapter except for the battery that is covered in Chapter Three. terlock switch (1987-on models), starter relay, battery and starter motor as shown in Figure 33. Each component of this system is covered separately in this chapter except for the battery that is covered in Chapter Three. 1. Drain the...

Master Cylinder

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 slave cylinder or the master cylinder can damage the components. Also, sharp tools must not be used...

Breakin

Following cylinder servicing (boring, honing, new rings, etc.) and major lower end work, the engine should be broken-in just as if it were new. The performance and service life of the engine depends greatly on a careful and sensible break-in. For the first 500 miles, no more than one-third throttle should be used and speed should be varied as much as possible within the one-third throttle limit. Prolonged, steady running at one speed, no matter how moderate, is to be avoided, as is hard...

Ball Bearing Replacement

Ball bearings (Figure 64) are used throughout your Suzuki's engine and chassis to reduce power loss, heat and noise resulting from friction. Because ball bearings are precision made parts, they must be maintained by proper lubrication and maintenance. When a bearing is found to be damaged, it should be replaced immediately. However, when installing a new bearing, care should be taken to prevent damage to the new bearing. While bearing replacement is described in the individual chapters where...

Secondary Gear Assembly

If the chain is damaged, also inspect the sprocket at each end as they may also be damaged. 7. Measure the camshaft chain for stretching as follows a. Place the chain on a flat surface and pull the chain taut to remove all slack. b. Use a vernier caliper and measure the distance between 21 pins (or 20 pitches) as shown in Figure 221. c. Repeat Steps 7a and 7b several times at various locations around the chain. The chain usually wears and stretches unevenly. It is important to

Electrical Components

This section contains information on ele components other than switches. Some of the is procedures covered in this section instruct takingll meter reading within the electrical connector ttj Speedometer and Indicator Lamp Housing Removal Installation b. Check each female end of the connector. Make sure that the metal connector on the end of each wire is pushed in all the way into the plastic connector. If not, carefully push them in with a narrow bladed screwdriver. c. Check all electrical...

Service Intervals

The services and intervals shown in Table 1 a recommended by the factory. Strict adherence) these recommendations will ensure long servl from the Suzuki. If the bike is run in an areaofhii humidity, the lubrication services must be donenra frequently to prevent possible rust damage. For convenience when maintaining your moa cycle, most of the services shown in these tables mi described in this chapter. However, some procedul which require more than minor disassembly oriij justment are covered...

Starter Clutch And Gears

The starter gears can be removed with the engine in the frame. This procedure is shown with the engine removed for clarity. Refer to Figure 77 for this procedure. 1. Remove the alternator stator assembly as described in this chapter. 2. Remove the starter idler gear No. 2 and its shaft (Figure 78). 3. Withdraw the No. 1 idler gear shaft (A, Figure 79) then remove the No. 1 idler gear (B, Figure 79). 4. Remove the alternator rotor assembly as described in this chapter.

Starter Relay

CAUTION When disconnecting the starter electrical 1 wire from the starter solenoid, do not touch the other electrical terminal of the starter relay this would result in a short. I 2. Disconnect the electrical wire (A, Figure 88> going from the starter relay to the starter. Leave lie other electrical wire connected to the relay. 3. Shift the transmission into NEUTRAL. 4. Turn the ignition switch ON. 5. Pull in on the clutch lever until it bottoms out 1. Remove the rider's seat and frame...

Carburetor Adjustments

To disconnect the No. 2 throttle cable, perform the following a. Loosen the locknut (A, Figure 64) and disconnect the cable end from the throttle wheel (B. Figure 64). b. Remove the No. 2 throttle cable (C, Figure 64) along with the No. 1 throttle cable (D, Figure 64) that was disconnected during carburetor removal. c. Remove the throttle cable assembly. 3. To remove the choke cable, perform the following a. Unscrew the nut (A, Figure 65) securing the choke cable to the front carburetor. b....

Tire Changing

The wheels can easily be damaged during tire removal. Special care must be taken with tire irons when changing a tire to avoid scratches and gouges to the outer rim surface. Insert scraps of leather between the tire iron and the rim to protect the rim from damage. The stock wire wheels are designed for use with tube type tires while the stock cast wheels are designed for use with tubeless tires. When removing a tubeless tire, take care not to damage the tire beads, inner liner of the tire or...

Engine Performance

In the following check list, it is assumed that the engine runs, but is not operating at peak performance. This will serve as a starting point from which to isolate a performance malfunction. a. Carburetor(s) incorrectly adjusted. b. Fouled or improperly gapped spark plug(s). d. Obstructed fuel line or fuel shutoff valve. f. Ignition timing incorrect due to defective ignition component(s). a. Fouled or improperly gapped spark plugs. b. Improper carburetor main jet selection. c. Ignition timing...

Lubricants

Periodic lubrication assures long life for any type of equipment. The type of lubricant used is just as important as the lubrication service itself, although in an emergency the wrong type of lubricant is better than none at all. The following paragraphs descriJ Engine Oil the types of lubricants most often used on motorqH cle equipment. Be sure to follow the manufacturer Four-cycle o recommendations for lubricant types. Generally, all liquid lubricants are called oil They may be mineral-based...

Front Cylinder Head Cover And Camshaft

Remove the engine from the frame as described in this chapter. 2. Remove the bolts securing the cylinder head side covers (Figure 15) and remove both side covers. 3. On the spark plug side of the cylinder head, remove the insulator (Figure 16). 4. Remove the bolts (A, Figure 17) securing the intake pipe (B, Figure 17) and remove it from the front cylinder. 5. Mark the valve adjuster covers with an F* and R so they will be reinstalled on the correct location. 6. Remove the valve adjuster covers...

Fuel Pump Circuit

Fan Motor Thermo Switch Removal Testing Installation The fan motor thermo switch controls the radiator fan according to engine coolant temperature. This switch is attached to the upper rear side of the radiator next to the inlet hose. Figure 159 is a schematic of the fan motor thermo switch circuit.

Primary Drive Gear

Remove the engine from the frame as described in this chapter. CAUTION The primary drive gear bolt has left-hand threads. Turn the wrench clockwise to loosen it and counterclockwise to tighten it. 2A. If the clutch assembly is still in place, perform the following a. Stuff shop cloth between the clutch outer housing gear and the primary drive gear (A, Figure 209). This will prevent the gear from rotating while loosening the bolt. b. Turn the wrench clockwise and loosen the primary drive gear...

How To Replace The Water Pump Seals On A Suzuki Intruder 700

Figure 29 is shown with the water pump removed from the crankcase, turned over, then set back into the crankcase to hold the assembly upside down in order to remove the E-clip. 1. Remove the E-clip (Figure 29) securing the shaft into the water pump housing. 2. Carefully withdraw the impeller and shaft out of the housing and mechanical seal (Figure 30). 3. If necessary, remove the impeller and pin from the shaft. 4. If the mechanical seal is removed, also remove the oil seal in the housing...

Chapter Four I Engi

Using needlenose pliers, reach into the crankcase and tum the water pump shaft so the raised tab is vertical (Figure 203). 4. Rotate the oil pump drive shaft so the groove (Figure 204) will also be vertical when the oil pump is installed into the crankcase. 5. Install the oil pump into the crankcase and align the oil pump drive shaft with the water pump shaft. If necessary, slightly rotate the oil pump shaft (B, Figure 202) back and forth to assure correct alignment. 6. Push the oil pump in...

1

Ter and measure tf an exact journal t 6. If the crankpir the bearing clear, gage. Correct bea 1. Remove Plasti 7. If the bearing use the following 8. The connectin code number 1, the inside diamet Connecting Rod Bearing and Oil Clearance Measurement 2. Check the connecting rod small end for wear or scoring. 3. Insert the piston pin into the connecting rod (Figure 295) and rotate it. Check for looseness or roughness. Replace the defective part. 4. Measure the inside diameter of the connecting...

Stroke Principles

As the piston travels downward, the exhaust valve is closed and the intake valve opens, allowing the new air-fuel mixture from the carburetor to be drawn into the cylinder. When the piston reaches the bottom of its travel (BDC), the intake valve closes and remains closed for the next 1 1 2 revolutions of the crankshaft. While the crankshaft continues to rotate, Uw piston moves upward, compressing the ait' fuel mixture. As the piston almost reaches the top of its travel, the spark plug fires,...

Slave Cylinder

CAUTION Cover the fuel tank, front fender and instrument duster 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 left-hand chrome cover (Figure 79) and remove the cover. 2. Remove the cap and attach a hose to the bleed al e (Figure on the s, a e cyiindet, then place...

Rtv Gasket Sealant

Room temperature vulcanizing (RTV) sealant is used on some pre-formed gaskets and to seal some components. RTV is a silicone gel supplied in tubes and can be purchased in a number of different colors. Moisture in the air causes RTV to cure. Always place the cap on the tube as soon as possible when using RTV sealants. RTV has a shelf life of one year and will not cure properly when the shelf life has expired. Check the expiration date on RTV tubes before using and keep partially used tubes...

Headlight

Unhook the clip (Figure 93) and remove the light bulb (Figure 94). Replace with a new bulb (Figure 95). 6. To remove the headlight lens unit, perform the following a. Remove the adjustment screws (Figure 96). 7. Install by reversing these removal steps, noting the following. a. Install the rubber cover with the TOP arrow (A, Figure 98) facing upward. b. Make sure the electrical connector (B, Figure 98) is on tight and that the rubber cover is properly installed to keep out moisture. c. Adjust...

Carburetor Service

Carburetor disassembly and assembly is separated into three different procedures. The piston valve assembly and coasting valve are basically the same on both the front and rear carburetor and is 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 a. Figure 13 front...

Side Stand Relay Suzuki 750 Intruder

Figure 164 is shown with the engine removed from the frame for clarity. 5. Unscrew the thermo sensor from the coolant inlet fitting (Figure 164) of the front cylinder head. WARNING Wear safety glasses or goggles and gloves during this test. Protect yourself accordingly as the coolant is heated to a very high temperature and can result in severe hums if not handled properly. 6. Suspend the thermo sensor in a small pan of 50 50 mixture of distilled water and coolant. The sensor must be...

Liquid Cooling System

The pressurized liquid cooling system consists of a radiator, water pump, thermostat, coolant reserve tank and a electric cooling fan. CAUTION Drain and flush the cooling system at least every 2 years. Refer to Coolant Change in Chapter Three. Refill with a mixture of ethylene glycol antifreeze (formulated for aluminum engines) and purified water. Do not reuse the old coolant as it deteriorates with use. Do not operate the cooling system with only purified water (even in climates where...

Excessive Vibration

Usually this is caused by loose engine mounting hardware. If not, it can be difficult to find without disassembling the engine. High speed vibration may be due to a bent axle shaft or loose or faulty suspension components. Vibration can also be caused by the following conditions d. Defective or damaged wheels. f. Internal engine wear or damage.

Camshaft

Inspect the camshaft bearing journals (A. Figure 66) for wear. 2. Measure both camshaft bearing journals with a micrometer. Refer to Figure 67 for the center journal and to Figure 68 for the end journal. Compare to the dimensions given in Table 3. If worn to the service limit or less the camshaft must be replaced. 3. Check the camshaft lobes (B, Figure 66) for wear. The lobes should show no signs of scoring and the edges should be square. Slight damage may be removed with a silicone carbide...

Suzuki Intruder 800 Seat Bolt

Refer to Figure 1 for this procedure. 1. Remove the right-hand frame side cover as described in this chapter. 2. Remove the bolt, lockwasher and washer (A, Figure 2) at the front on each side. 3. Pull up on the front of the seat (B, Figure 2) and move (he seat toward the front to disengage it from the rear retaining bracket on the pillion seat. 4. Partially remove the seat. Carefully remove the sidestand check relay (Figure 3) from the base of the seat. 6. To install, move the seat onto the...

Cooling System Check

Two checks should be made before disassembly if a cooling system fault is suspected. 1. Run the engine until it reaches operating temperature. While the engine is running a pressure surge should be felt when the water pump outlet hose (Figure 2), is squeezed. 2. If a substantial coolant loss is noted, one of the head gaskets may be blown. In extreme cases sufficient coolant will leak into a cylinder(s) when the bike is left standing for several hours so the engine cannot be turned over with the...

Chapter Twelve

Completely unscrew the adjustment nut (Figure 87) on the end of the brake cable. 4. Remove the brake cable from the receptacle (Figure 91) on the brake panel. 5. Remove the bolts and washers securing the cover (Figure 92) and remove the cover. 6. Disconnect the brake light switch return spring (Figure 93) from the brake light switch cable. 7. Slide the rubber boot (Figure 94) off the end of the brake light switch cable. Front master cylinder Clamping bolts Union bolt Front caliper Bleed valve...

Correct Way To Grind

Figure 32 shows several pliers useful in repairing your Suzuki. Each type of pliers has a specialized function. Slip-joint pliers are general purpose pliers and are used mainly for holding things and for bending. Needlenose pliers are used to hold or bend small objects. Water pump pliers can be adjusted to hold various sizes of objects the jaws remain parallel to grip around objects such as pipe or tubing. There are many more types of pliers. CAUTION Pliers should not...

Electrical Connectors

The Suzuki Interceptor is equipped with many electrical components, connectors and wires. Corro-sion-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 in a dielectric grease compound. Dielectric grease is especially formulated for sealing and...

Suzuki Intruder 800 Fork Removal Tools

If it is necessary to remove the components from the handlebar for service, perform this procedure. If component removal is not necessary, only the removal of the handlebar assembly refer to the preceding procedure. 1. Remove the screws securing the right-hand handlebar switch assembly (Figure 48) together. 2. Partially remove the upper half and disconnect the throttle cable from the throttle assembly. Carefully lay the throttle cable over the fender or back over the frame. Be careful that the...

Transistorized Ignition System

The Intruder is equipped with a solid-state, transistorized ignition system that uses no breaker points. The ignition circuit is shown Figure 28. The signal generator consists of a raised tab on the alternator rotor and signal generator(s), attached to the alternator cover next to the alternator stator coil assembly. As the alternator rotor is turned by the crankshaft the raised tab passes the pickup coil(s) and a signal is sent to the ignition unit. This signal turns the ignitor unit...

Engine Mounting Hardware

Inting bracket inting bracket ar through bolt unting bracket ushion 16. Disconnect the crankcase breather hose from the rear cylinder head. 17. Remove the bolt (Figure 7) securing the gearshift lever and remove the lever. Reinstall the bolt in the lever to avoid misplacing it. 18. Remove the footpeg assembly as described in Chapter Thirteen. 19. Place wood block(s) and a small hydraulic jack under the engine to support it securely. 20. Take a final look all over the engine to make sure...

Umb

Use an ohmmeter and check for continuity between one of the end terminals on the diode and the center terminal. There should be continuity (low resistance) in one direction and no continuity (infinite resistance) with the test leads reversed. 5. Repeat Step 4 with the other end terminal and the center terminal. 6. If the diode fails either of these tests, the diode is defective and must be replaced. 7. Attach the electrical connector to the diode and make sure the electrical connector is free...

Battery Negative Terminal

Some of the component replacement procedures and some of the test procedures in this chapter require disconnecting the battery negative (-) lead as a safety precaution. 1. Remove the bolt and disconnect the battery negative (Figure 1) lead. 2. Reach into the battery case and move the negative lead out of the way so it will not accidentally make contact with the battery negative terminal. 3. Connect the battery negative lead to the terminal and tighten the bolt securely.

Pistons And Piston Rings

Check that the Finish has a smooth and velvety surface, it should not be shiny or highly polished. The final seating will take place when the engine is first run. 11. Repeat Steps 1-10 for all remaining valve seats. 12. Thoroughly clean the cylinder head and all valve components in solvent or detergent and hot water. 13. Install the valve assemblies as described in this chapter and fill the ports with solvent to check for leaks. If any leaks are present, the valve seats must 1. Remove the...

Crankshaft And Connecting Rods

Removal Installation Refer to Figure 281 for this procedure. asher rasher ' camshaft rocket gear asher rasher ' camshaft rocket gear 1. Split the crankcase as described in this chapter. 2. Remove the crankshaft assembly (Figure 282) from the left-hand crankcase half. 3. Remove the inner thrust washer (Figure 283) from the right-hand end of the crankshaft. 4. Remove the connecting rod cap bolt nuts (Figure 284) and separate the rods from the crankshaft.

Precision Measuring Tools

Measurement is an important part of motorcycle 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 valve clearance, engine compression and spark plug gap. As you get deeper into engine disassembly and service, measurements will be required to determine the size and condition of the piston and cylinder bore, valve and guide wear, camshaft wear, crankshaft runout and so on. When making...

Front Suspension And Steering

Poor handling may be caused by improper tire pressure, a damaged or bent frame or front steering components, worn wheel bearings or dragging brakes. Possible causes of suspension and steering malfunctions are listed in the following. b. Loose or worn steering head bearings. c. Excessive wheel hub bearing play. i. Bent or damaged steering stem or frame (at steering neck). k. Excessive front end loading from non-standard equipment. 1. Damaged fairing assembly, m. Loose fairing mounts or brackets....

Cylinder Bore Gauge

The cylinder bore gauge is a very specialized precision tool. The gauge set shown in Figure 48 is comprised of a dial indicator, handle and a number of length adapters to adapt the gauge to different bore sizes. The bore gauge can be used to make cylinder bore measurements such as bore size, taper and out-of-round. Depending on the bore gauge, it can sometimes be used to measure brake caliper and master cylinder bore sizes. An outside micrometer must be used together with the bore gauge to...

Carburetor Assembly

Remove the 2 carburetors and the throttle cable assembly that is attached to both carburetors as an assembled unit. 1. Remove the seat(s) as described under Seal Removal Installation in Chapter Thirteen. 2. Remove the fuel tank as described in this chapter. 3. Disconnect the battery negative lead as described in Chapter Three. 4. Remove the screws securing both the right- and left-hand frame head side covers (Figure 1). Remove both side covers. 5. Remove the bolts securing the fuel tank...

Rear Air Filter Housing

Breather hose 10. Drain hose 5. Remove the cable bands from the inlet pipe and move the cables out of the way. 6. Remove the inlet pipe (B, Figure 66) from the front air filter element and the carburetor inlet. Remove the front inlet pipe. 7. Remove the 3 bolts securing the air filter element (Figure 67) to the air filter case and remove the element from the air box. 8. Inspect the element as described in this chapter. 9. Install the air filter element and make...

External And Internal Shift Mechanism

Motorcycle Mechanism

Withdraw the gearshift shaft (Figure 4) from the crankcase. See information regarding a bent gearshift shaft in the introductory paragraph of this procedure. 4. Remove the bolt (Figure 5) securing the cam gear assembly. 5. Remove the nuts (A, Figure 6) securing the pawl retainer (B, Figure 6) and remove the pawl retainer. 6. Remove the screws securing the cam guide (Figure 7) and remove the cam guide. 7. Unhook the spring (Figure 8) from the stopper arm. 8. Remove the cam gear assembly (Figure...

Engine Will Not I

Make sure the engine stop switch Figure 3 is not in the OFF position. 4. Is the choke in the correct position The choke knob should be pulled out Figure 4 for a cold engine and pushed in Figure 5 for a warm engine. A compression test shows how much pressure builds in a cylinder during starting. If the compression falls below specified levels, the engine will become difficult to start or will not start. Refer to Compression Testing in Chapter Three. Interpret results as follows a. Normal Perform...

Charging System

The charging system consists of the battery, alternator and a solid-state voltage regulator rectifier Figure 2 . Alternating current generated by the alternator is rectified to direct current. The voltage regulator maintains constant voltage to the battery and electrical loads lights, ignition, etc. regardless engine speed and load. A malfunction in the charging system generally causes the battery to remain undercharged. To prevent damage to the alternator and the regulator rectifier when...

External Gearshift Mechanism

Motorcycle Gear Shift Drum Mechanism

The external gearshift mechanism is located on the same side of the crankcase as the clutch assembly. To remove the internal shift mechanism shift drum and shift forks , it is necessary to remove the engine and split the crankcase as described in Chapter Four. The gearshift lever is subject to a lot of abuse. If the bike has been in a hard spill, the gearshift lever may have been hit and the gearshift shaft bent. It is very hard to straighten the shaft without subjecting the crankcase halves to...

Rear Carburetor Assembly

Install the gasket Figure 46 into the float bowl. Make sure it seats completely. 13. Install the float bowl and screws Figure 40 . Tighten the screws securely. 14. After the carburetors have been disassembled the idle speed should be adjusted and the carburetors synchronized as described in this chapter.

Engine Fails to Start

If the bike will not start, perform the following checks in order WARNING Do not use an open flame to check in the tank. A serious explosion is certain to result. 1. Is there fuel in the tank Remove or open the filler cap Figure 1 and rock the bike. Listen for fuel sloshing around. 2. Is the fuel shutoff valve in the ON position Figure 2 and on models so equipped, is the vacuum line to the valve from the engine still connected

Clutch Slave Cylinder

CAUTION In the following step, do not use a sharp tool to remove the piston seal from the piston. Do not damage the piston surface. 7. Use a piece of plastic or wood and carefully remove the piston seal from the piston. Discard the piston seal as it must be replaced. 8. Inspect the slave cylinder body Figure 89 for damage. If damaged, replace the slave cylinder as an assembly. The body cannot be replaced separately. 9. Inspect the hydraulic fluid passageway Figure 90 at base of the piston bore....

Crankcase

Service to the lower end requires that the crank-case assembly be removed from the motorcycle frame and disassembled split . 1. Remove the engine as described in this chapter. 2. Remove the following exterior assemblies from the crankcase assembly a. Cylinder head and cylinder assemblies this chapter. c. Starter clutch assembly Chapter Eight. d. Oil sump and filter this chapter. e. External shift mechanism Chapter Six. h. Starter motor Chapter Eight. i. Neutral switch Chapter Eight, j. Oil...

Fuel Pump

Rear Fender Fuel Filler Install

The electromagnetic fuel pump is located on the left-hand side of the bike below one of the ignition coils. Fuel pump testing procedures are located in Chapter Eight. WARNING Some fuel may spill in the following procedure. Work in a well-ventilated area at least 50 feet 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 under Seat Removal Installation in...

Engine Oil Level Check and Adding

Engine oil level is checked with the oil level inspection window, located at the right-hand side of the engine on the clutch cover. 1. Place the bike on the sidestand on level ground. 2. Start the engine and let it idle for 1 -2 minutes. 3. Shut off the engine and let the oil settle for 1-2 minutes. 4. Hold the bike in the true vertical position. A false reading will be given if the bike is tipped to either side. 5. Look at the oil level inspection window. The oil level should be between the 2...

Engine

Four-cycle oil for motorcycle and automotive engines is graded by the American Petroleum Institute API and the Society of Automotive Engineers SAE in several categories. Oil containers display these ratings on the lop or label. API oil grade is indicated by letters oils for gasoline engines are identified by an S. Suzuki models described in this manual require SE or SF graded oil. Viscosity is an indication of the oil's thickness. The SAE uses numbers to indicate viscosity thin oils have low...

Thermostat And Housing

Water Pump Suzuki Intruder 800

The thermostat is located on the side of the water pump on the left-hand side of the engine just forward of the swing arm left-hand pivot point. 1. Drain the cooling system as described under Coolant Change in Chapter Three. 2. Remove the bolts A, Figure 16 and acorn nut B, Figure 16 securing the water pump trim cover and remove the cover. 3. Loosen the clamping screw on the water pump inlet hose clamps. Move the clamps back onto the hose and off of the neck of the fitting on the frame rail and...

Front Brake Pad Replacement

There is no recommended mileage interval for changing the friction pads in the disc brakes. Pad wear depends greatly on riding habits and conditions. The pads should be checked for wear every 6 months and replaced when the wear indicator reaches the edge of the brake disc. To maintain an even brake pressure on the disc, always replace both pads in the caliper at the same time. Disconnecting the hydraulic brake hose from the brake caliper is not necessary for brake pad replacement. Disconnect...

Front Brake Hose Replacement

Suzuki recommends replacing the brake hose every four years or when it shows signs of cracking or damage. CAUTION Cover the surrounding area with a heavy cloth or plastic tarp to protect them from accidental brake fluid spills. Wash brake fluid off any painted or plated surfaces or plastic parts immediately, as it will destroy the finish. Use soapy water and rinse completely. 1. Remove the cap from the bleed screw Figure 57 on the front caliper. 2. Attach a piece of hose to the bleed screw and...

Cylinder Head And Cylinder

The cylinder head and cylinder are removed from the crankcase as an assembly then separated after removal. 1. Remove the bolts A, Figure 86 securing the intake pipe and remove it B, Figure 86 . 2. Remove the cylinder head covers as described in this chapter. 3. Loosen the sfirews of the clamping bands Figure 87 on the short coolant hose connecting both cylinder heads. Move the clamps from the fittings of the cylinder heads and back onto the hose. 4. Loosen the screws of the clamping bands on...

Battery Electrical Cable Connectors

To ensure good electrical contact between I battery and the electrical cables, the cables musty clean and free of corrosion. Oil is gra an indicatu Automotive oil viscosity viscosity nt SAE 5 oil relatively tli weather it is SAE 10W. 1. If the electrical cable terminals are badly i Bf f ' U roded, disconnect them from the bike's elecml A ,,00 j c 2. Thoroughly clean each connector with a m parts as easil brush and then with a baking soda solution. Ru thoroughly with clean water and wipe dry...

Rear Suspension And Final Drive

This chapter includes repair and replacement procedures for the rear wheel and rear suspension components. Tire changing and wheel balancing are covered in Chapter Ten. Refer to Table 1 for rear suspension torque specifications. Table 1 is located at the end of this chapter. 1. Block up the engine so that the rear wheel clears the ground. 2. Completely unscrew the rear brake adjusting nut Figure 1 . 3. Depress the brake pedal and remove the brake rod, or cable, from the pivot joint in the brake...

Steering Head Bearing Races

The headset and steering stem bearing races are pressed into the headset portion of the frame. The races are easily bent, so they should not be removed unless they require replacement. Headset Bearing Race Removal Installation 1. Remove the steering stem as described in this chapter. 2A. A special Suzuki tool set-up Suzuki bearing outer race remover part No. 09941-54911, steering bearing remover installer part No. 09941-74910 can be used to remove the headset bearing race as follows a. Install...

Periodic Maintenance

Ball bearings used in the steer-x removed, cleaned and lubri-grease as described in Chapter iricator and wipe off all excess able. meter cable into the speedome-the front wheel, upper end of the speedometi neter housing. The fluid level should be up between the upper and lower mark within the reservoir. If the brake fluid level reaches the lower level mark Figure 50 The hydraulic fluid in the clutch master cylinder should be checked as listed in Table 1 or whenever the level drops, whichever...

Rear Drum Brake

Forearms thoroughly after completing the work. forearms thoroughly after completing the work. 1. Remove the rear wheel as described in Chapter Eleven. 2. Pull the brake assembly straight up and out of the brake drum. 3. Carefully pull up on both brake shoes in a V-for-mation Figure 74 and remove the brake shoes and return springs as an assembly. 4. Disconnect the return springs from the brake shoes. 5. If necessary, remove the bolt Figure 75 securing the brake arm and remove the brake arm,...

Engine Oil and Oil Filter Change

Change the engine oil and the oil filter at the same time at the factory-recommended oil change interval indicated in Table 1. This assumes that the motorcycle is operated in moderate climates. In extreme climates, oil should be changed every 30 days. The time interval is more important than the mileage interval because acids formed by combustion blowby will contaminate the oil even if the motorcycle is not run for several months. If the motorcycle is operated under dusty conditions, the oil...

Inflatable Band For Tubeless Tiire

Step 4B relates to metal valve stems on tubeless tire only. 4B. On tubeless tires, install a new valve stem as follows a. Insert the new valve stem into the rim. b. Install the nut and tighten with your fingers only. Do not use pliers and overtighten the nut as it may distort the rubber sealing grommet that could result in an air leak. c. Hold onto the nut and install and tighten the locknut securely. d. Inspect the valve stem core rubber seal for hardness or deterioration. Replace the valve...