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1987-2003 SUZUKI VS1400 INTRUDER SERVICE REPAIR MANUAL

1998-2000 Suzuki VL1500 Intruder Volusia 1998-2000 Service Manual


2005-2009 Suzuki VL1500 Intruder Boulevard Service Repair Manual
 
 
 
SUZUKI MODELS

1985 Suzuki VS800GL Intruder VS800 VS-800
1986 Suzuki VS700GLE FG Intruder VS700 VS-700 GLE FG
1986 Suzuki VS700GLE DG Intruder VS700 VS-700 GLE DG
1986 Suzuki VS700GL FG Intruder VS700 VS-700 GL FG
1986 Suzuki VS700GL DG Intruder
1987 VS1400GLP & GLF Intruder UK Models
1987 VS1400GLFH Intruder
1988 VS1400GLP & GLF Intruder UK Models
1988 VS1400GL US Dygi
1989 VS1400GLP & GLF Intruder UK Models
1990 VS1400GLP & GLF Intruder US & UK Models
1991 VS1400GLPM & GLF Intruder US & UK Models
1992 VS1400GLPN & GLF Intruder US & UK Models
1993 VS1400GLPP & GLF Intruder US & UK Models
1994 VS1400GLPR & GLF Intruder US & UK Models
1995 VS1400GLPS & GLF Intruder US & UK Models
1996 VS1400GLPT & GLF Intruder US & UK Models
1997 VS1400GLPV & GLF Intruder US & UK Models
1998 VS1400GLPW & GLF Intruder US/UK
1999 VS1400GLPX Intruder
2000 VS1400GLPY Intruder
2001 VS1400GLPK1 Intruder
2002 VS1400GLPK2 Intruder
2002 VS1400GLFK2 Intruder
2003 VS1400GLPK3 Intruder
2003 VS1400GLFK3 Intruder
1987 Suzuki VS750 Intruder (UK) VS750 VS-750
1987 Suzuki VS700GLPH Intruder VS700 VS-700 GLPH
1987 Suzuki VS700GLEFH Intruder VS700 GLEFH
1988 Suzuki VS750GLPJ Intruder VS750 VS-750 GLPJ
1988 Suzuki VS750GLF Intruder (UK) GLF
1989 Suzuki VS750GLPK Intruder GLPK
1989 Suzuki VS750 Intruder (UK)
1990 Suzuki VS750GLPL Intruder GLPL
1990 Suzuki VS750 Intruder (UK) VS-750
1991 Suzuki VS750GLPM Intruder GLPM
1991 Suzuki VS750 Intruder (UK)
1992 Suzuki VS800GLPN Intruder VS800 VS-800 GLPN
1993 Suzuki VS800GLP Intruder VS800 VS-800 GLP
1994 Suzuki VS800GLR Intruder GLR
1995 Suzuki VS800GLS Intruder GLS
1996 Suzuki VS800GLT Intruder GLT
1997 Suzuki VS800GLV Intruder GLV
1998 Suzuki VS800GLW Intruder GLW
1999 Suzuki VS800GLX Intruder GLX
2000 Suzuki VS800GLY Intruder GLY
2001 Suzuki VS800GL Intruder GL
2002 Suzuki VS800GL Intruder GL
2003 Suzuki VS800GL Intruder GL
2004 Suzuki VS800GL Intruder S50
1998 Suzuki 1500
1999 Suzuki 1500
1999 Suzuki 1500
2000 Suzuki 1500
2001 Suzuki 1500
2002 Suzuki 1500
2003 Suzuki 1500
2004 Suzuki 1500
2005 Suzuki C90T Boulevard 1474cc
2005 Suzuki C90 Boulevard 1474cc
2005 Suzuki VL1500 Intruder LC C90 VL-1500
2006 Suzuki VL1500 Intruder LC C90 VL-1500
2007 Suzuki VL1500 Boulevard C90 VL-1500
2007 Suzuki VL1500 Boulevard C90T VL-1500
2008 Suzuki VL1500 Boulevard C90T
2008 Suzuki VL1500 Boulevard C90
2009 Suzuki VL1500T Boulevard C90T
2009 Suzuki VL1500 Boulevard C90
2005 Suzuki VS800 Intruder S50 VS-800
2006 Suzuki VS800 Boulevard S50 VS-800
2007 Suzuki VS800 Boulevard S50
2007 Suzuki VS800 Boulevard S50
2007 Suzuki VS800
2008 Suzuki VS800 Boulevard S50 800
2008 Suzuki VS800 Boulevard S50 800
2008 Suzuki VS800 Boulevard S50 800
2009 Suzuki VS800 Boulevard S50 800
1
COMMON SUZUKI SEARCHES:


 GAUGES AND INSTRUMENTS 2.1
GENERAL
Use the troubleshooting tables on the following pages to
diagnose and locate problems with malfunctioning or inoperative
instruments and gauges. For wire connections at rear of
gauges, see Figure 2-1. Refer to the applicable wiring diagram
at the back of this book for further assistance.
DIAGNOSTICS
Fuel Level Gauge
When the Ignition/Light Key Switch is turned to IGNITION,
the fuel gauge is connected to + 12 vdc. Current flows
through the gauge and variable resistor in the fuel level
sender to ground. The sender unit float controls the amount
of resistance in the variable resistor.
Fuel Level Sender Test
1. See the following chart and “ground” the applicable test
point.
2. Turn the Ignition/Light Key Switch to IGNITION. If gauge
indicated FULL, gauge is functioning correctly. Proceed
to step 3. If gauge did not indicate FULL, proceed to step
4.
3. With the Multi-Meter, Part No. HD-35500A, set on the
RXI scale, measure the resistance of the sender unit.
Place one probe on the center terminal and the other
probe on a good ground.

Oil Pressure Gauge and Indicator Light
Problem:
Low oil pressure light remains on with engine
running above idle and/or oil pressure gauge does not work.
Ambient Air Temperature Gauge
Problem:
Gauge inoperative.
Cause Solution
No oil pressure due to lack of oil or
faulty oil pump.
Running engine when OIL pressure light remains on and gauge indicates
low pressure will result in engine damage.
1. Check oil level. Add oil if low.
2. Restart engine and verify that oil pressure light goes off and gauge indicates
pressure. If problem still exists, refer to OIL PUMP in the Service
Manual (Part Number 99483-02).
Contacts in pressure sending unit
not opening to shut off light.
Variable resistor in sender is
shorted to ground.
1. Locate the oil pressure sending unit on the front right side of the crankcase.
2. Verify that the electrical connector is properly connected to the sending unit.
3. If the oil pressure gauge indicates pressure but the low oil pressure light remains
on, proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Place one
ohmmeter probe on indicator lamp terminal (closest to latch), place the other
probe on the crankcase. Meter must read zero ohms.
b. Start the engine and run at a fast idle. The ohmmeter must read infinity.
c. Replace the sending unit if the above meter readings are
not
obtained.
4. If the low oil pressure light functions correctly, but the pressure gauge does not,
then proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Turn the Ignition/
Light Key Switch to IGNITION. The gauge must read zero.
b. Ground BN/GN wire terminal to crankcase. The gauge must read full scale 70
PSI.
c. Replace the sending unit if the above gauge readings are obtained. If the
gauge readings are
not
obtained, then replace the pressure gauge.
No power to gauge. See Voltmeter.
CAUTION
Cause Solution
Sensor not grounded or open
between sensor and gauge.
Test for continuity between pin 1 and ground and pin 3 and gauge. Repair if open.
Broken or disconnected power or
ground wire to gauge.
Check for 12 vdc between pins 1 and 3 at connector [115A]. Replace gauge if voltage
is present. Use voltage drop tests and continuity checks to isolate if voltage is not
present.
Malfunction in gauge or sensor.
Measure resistance between pins 1 and 3 at 65° to 85° F. Resistance should be 43-31
ohms. Replace sensor if out of range, replace gauge if within range.
Instruments
HOME
Voltmeter
Problem:
Meter inoperative.
Indicator Lights: FLHR/C
Problem:
Light(s) inoperative.
Cause Solution
Broken or disconnected leads to meter
or open meter winding.
1. With Ignition/Light Key Switch turned to IGNITION, verify that 12 vdc is
present at “±” terminal on voltmeter. With switch turned to OFF, check
ground terminal for continuity to ground.
2. Replace the voltmeter if 12 vdc is present and ground terminal is grounded.
3. If 12 vdc is not present, trace wiring until disconnected or broken wire is
found and repair as necessary. If ground terminal is not grounded, refer to
wiring diagram and repeat procedure given for 12 vdc lead.
Ground Present at Pin
2 of Connector [21A]?
Ground through switch
Ground through switch
Oil Pressure Indicator
Neutral Indicator
High Beam Indicator
R/L Turn Indicator 12V when active
Oil Pressure or Neutral Indicator High Beam or R/L Turn Signal Indicator
Check for 12V at
Pin 6 of Connector
[21A]. Is 12V
Present?
Replace Indicator
Lights Assembly.
Is 12V Present when
Circuit is Active?
NOTE
Use Pin 1 (Left Turn),
Pin 4 (Right Turn) and
Pin 2 (High Beam).
Locate and
Repair Open
in Circuit.
Replace Indicator
Lights Assembly.
NOTE
12V when active
Indicator Lights Connector [21]
Terminal Wire Color Indicator
1 Violet Left Turn
2 White High Beam
3 Green/Yellow Oil Pressure
4 Brown Right Turn
5 Tan Neutral
6 Orange Neutral/Oil Pressure
7 Black Right/Left Turn/High Beam
8 Not Used Not Used
Replace Oil
Pressure
Switch.
Repair Open in GN/Y
Wire (Oil psi) or TN
Wire (Neutral).
5161
Replace
Neutral Switch.
Is There Continuity
to Ground Through
Switch?
5191
5048
5157
5048
5048
Locate and
Repair Open
in Circuit.
5048
5191
YES NO
1
YES
Is There Continuity to
Ground at Pin 5 (Neutral)
and Pin 3 (Oil psi) of
Connector [21]?
Check Fuses
or Find Open.
YES NO NO
NO
2
NO
NO
YES
YES
Will Not Function Will Not Function
Instruments 2-5
HOME
SPEEDOMETER 2.2
GENERAL
NOTE
The performance (proper operation and sweeping action) of
the speedometer can be evaluated using the Speedometer
Tester (HD-41354). Before replacing the speedometer, see
Section 2.3 SPEEDOMETER PERFORMANCE CHECK.
The electronic speedometer consists of a speed sensor,
reset switch and speedometer unit.
The Hall-Effect speed sensor circuitry is triggered by the
teeth of the transmission mainshaft 4th gear. The sensor output
is a series of pulses that are interpreted by the speedometer
circuitry to control the position of the speedometer
needle and the odometer’s liquid crystal display (LCD). The
odometer mileage is permanently stored and is not lost when
electrical power is turned off or disconnected.
NOTE
Circuitry in the speedometer also conditions the sensor input
to provide an input to the turn signal canceler.
By momentarily pressing the reset switch, the user is able to
toggle between the odometer and trip odometer displays. To
zero the trip odometer, depress and hold the reset switch
while the odometer display is visible. The trip odometer mileage
will then appear for approximately 2-3 seconds, after
which time the recorded figure is zeroed.
The odometer can display seven numbers to indicate a maximum
of 999999.9 miles. The trip odometer can display five
numbers for a maximum of 9999.9 miles.
Reset Switch
See Figure 2-2. Besides toggling between the odometer and
trip odometer displays, the reset switch is also used to identify
the speedometer pulses per unit and to enter the diagnostic
mode. In the diagnostic mode, the user can display the
fault codes stored in memory. The fault codes assist the user
in troubleshooting speedometer problems.
Diagnostic Mode
To enter the diagnostic mode, hold the reset switch in and
turn the Ignition/Light Key Switch from OFF to IGNITION. The
normal power-up sequence occurs before the diagnostic
mode is entered. Any diagnostic codes set during this powerup
sequence also will be stored.
IMPORTANT NOTE
Holding the reset switch in for more than 5 seconds while in
the diagnostic mode will clear all set diagnostic codes from
memory.

SCHEDULED MAINTENANCE TABLE 1.4
The scheduled maintenance table beginning on this page
lists the maintenance requirements for Touring model motorcycles.
If you are familiar with the procedures, just reference
the table for the recommended maintenance interval as well
as the required specifications. On the other hand, if more
information is needed, simply turn to page 14 for the start of
more detailed service procedures. For your added convenience,
the adjacent chart lists the part numbers of the
required lubricants.
Lubricant Part Number
Engine Oil See Table 1-1.
Front Fork Oil
Hydraulic Fork Oil, Type “E”,
H-D Part No. 99884-80/16 oz.
Silicone Brake Fluid
D.O.T. 5 Hydraulic Brake Fluid,
H-D Part No. 99902-77/12 oz.
Transmission Lubricant
Semi-Synthetic Transmission Lubricant,
Part Nos. 98853-96/case qt.,
98852-96/case gal.
Chaincase Lubricant
Primary Chaincase Lubricant,
Part Nos. 99887-84/qt., 99886-84/gal.
Clutch and Throttle Cable
Lubricant
Super Oil, Part No. 94968-85TV
Steering Head Bearing
Lubricant
Special Purpose Grease,
Part No. 99857-97/cartridge
Electrical Contact
Lubricant
Electrical Contact Grease,
Part No. 99861-90

SPARK PLUG
NOTE
Be sure spark plugs are gapped to specification before
installation.
TORQUE VALUES
Part No. No. Size Gap
32317-86A 6R12 12 mm
0.038-0.043 in.
0.97-1.09 mm
Item ft/in-lbs Nm
Ignition module socket
head screws
50-60
in-lbs
5.7-6.8 Nm
MAP sensor TORX screw 25-35
in-lbs
2.8-4.0 Nm
Ignition coil bracket
socket screws
84-144
in-lbs
9.5-16.3 Nm
Spark plug 12-18 ft-lbs 16-24 Nm
Stator to crankcase TORX
screws
55-75
in-lbs
6.2-8.5 Nm
Battery cable bolt 60-96
in-lbs
6.8-10.9 Nm
Voltage regulator locknuts 70-100
in-lbs
7.9-11.3 Nm
Main 40 amp circuit
breaker Keps nuts
20-35
in-lbs
2.3-4.0 Nm
Battery hold-down clamp
TORX bolt 15-20 ft-lbs 20-27 Nm
Passing lamp bracket fork
side TORX bolts
15-20 ft-lbs 20-27 Nm
Passing lamp bracket fork
side stud acorn nuts
72-108
in-lbs
8.1-12.2 Nm
Tail lamp lense screws 20-24
in-lbs
2.3-2.7 Nm
Tail lamp circuit board/
plastic bracket
40-48
in-lbs
4.5-5.4 Nm
Rear fender tip lamp nuts 20-25
in-lbs
2.3-2.8 Nm
Front fender tip lamp nuts 20-25
in-lbs
2.3 - 2.8 Nm
Front fender trim strip tee
bolt nuts
10-15
in-lbs
1.1-1.7 Nm
Ignition switch to triple
clamp screws
36-60
in-lbs
4.1-6.8 Nm
Fairing cap TORX screws 25-30
in-lbs
2.8-3.4 Nm
Ignition switch button
head screws
18-23
in-lbs
2.0-2.6 Nm
Instrument bezel TORX
screws
25-35
in-lbs
2.8-4.0 Nm
Continued ...
Item ft/in-lbs Nm
Handlebar clamp to
master cylinder housing
screws
60-80
in-lbs
6.8-9.0 Nm
Lower and upper handlebar
switch housing TORX
screws
35-45
in-lbs
4-5 Nm
Handlebar clamp to
clutch lever bracket TORX
screws
60-80
in-lbs
6.8-9.0 Nm
Neutral switch 10-15 ft-lbs 14-20 Nm
Horn stud flange nut
(10mm)
80-100
in-lbs
9.0-11.3 Nm

Horn bracket acorn nut to
rubber mount stud
80-100
in-lbs
9.0-11.3 Nm
2 inch diameter gauge
nuts
10-20
in-lbs
1.1-2.3 Nm
Tachometer bracket
socket screws 10-20
in-lbs
1.1-2.3 Nm
Speedometer speed
sensor screw
84-108
in-lbs
9-12 Nm
Speedometer bracket
socket screws
10-20
in-lbs
1.1-2.3 Nm
Console mounting bolt
acorn nut
50-90
in-lbs
5.7-10.2 Nm
Fuel level sender plate
screws
18-24
in-lbs
2.0-2.7 Nm
Cruise module locknuts 60-96
in-lbs
6.8-10.9 Nm
Radio to support bracket
socket screws
35-45
in-lbs
4.0-5.1 Nm
Upper fairing speaker
lower TORX screw
22-28
in-lbs
2.5-3.2 Nm
Upper fairing speaker
upper TORX screws

SPECIFICATIONS 3.1
MANUFACTURING TOLERANCES
General
Number of cylinders 2
Type 4-cycle, 45°V
2
, air-cooled
Torque
86 ft-lbs (108.8 Nm) @ 3500
rpm, chrome duals exhaust
Bore 3.75 in. (95.25 mm)
Stroke 4.00 in. (101.6 mm)
Piston displacement (approx.) 88 cu. in. (1450 cc)
Compression ratio 9.0:1
Combustion chamber 5.187 cu. in. (85 cc) bathtub
Cam system
Twin cams, chain driven with
spring loaded tensioners
Max. sustained engine speed 5500 rpm
Idle speed 1000 rpm +/- 50
Weight 165 lbs (74.8 kg)
Ignition System
Type
Sequential, non waste spark,
MAP-N control
Ignition timing:
1050 rpm (Hot Idle)
20
o
-30
o
Spark plug size 12 mm
Spark plug type  6R12
Spark plug gap 0.038-0.043 in. (0.97-1.09 mm)
Spark plug torque 12-18 ft-lbs (16-24 Nm)
Oiling System
Pump
Twin gerotor, dual scavenge, crank mounted
and driven, internal oil pump, dry sump
Pressure
30-38 psi (207-262 kN/m
2
) at
2000 rpm and normal operating temperature
of 230
o
F (110
o
C)
Filtration
10 micron media,
filtered between pump and engine
Rocker Arm IN. MM
Shaft fit in bushing
(loose)
0.0005-0.0020 0.013-0.051
End clearance 0.003-0.013 0.08-0.033
Bushing fit in rocker arm
(tight)
0.002-0.004 0.051-0.102
Rocker Arm Shaft IN. MM
Shaft fit in rocker arm
support plate (loose)
0.0007-0.0022 0.018-0.056
Hydraulic Lifter IN. MM
Fit in crankcase (loose) 0.0008-0.0020 0.02-0.05
Cylinder Head IN. MM
Valve guide in head (tight) 0.0020-0.0033 .0060.051-0.084
Valve seat in head (tight) 0.003-0.0045 0.076-0.114
Head gasket surface
(flatness)
0.006 0.0152
Valve IN. MM
Fit in guide: exhaust 0.0015-0.0033 0.038-0.084
Fit in guide: intake 0.0008-0.0026 0.020-0.066
Seat width 0.040-0.062 1.02-1.58
Stem protrusion from
cylinder head boss
1.990-2.024 50.55-51.41
Valve Spring Outer Inner
Closed
72-92 lbs
@ 1.751-1.848 in.
38-49 lbs
@ 1.577-1.683 in.
33-42 kg
@ 44.45-46.9 mm
17-22 kg
@ 40.1-42.8 mm
Open
183-207 lbs
@ 1.282-1.378 in.
98-112 lbs
@ 1.107-1.213 in.
83-94 kg
@ 32.6-35.0 mm
44-51 kg
@ 28.1-30.8 mm
Free length
2.105-2.177 in. 1.926-1.996 in.
53.47-55.3 mm 48.9-50.7 mm
Piston IN. MM
Fit in cylinder 0.0006-0.0017 0.015-0.043
Ring end gap:
Top compression ring
2nd compression ring
Oil control ring
0.010-0.020
0.014-0.024
0.010-0.050
0.25-0.51
0.36-0.61
0.25-1.27
Ring side clearance:
Top compression ring
2nd compression ring
Oil control ring
0.0012-0.0037
0.0012-0.0037
0.0031-0.0091
0.030-0.094
0.030-0.094
0.079-0.23
Piston pin fit (loose) 0.0003-0.0005 0.008- 0.013
Engine
HOME
MANUFACTURING TOLERANCES (CONT.)
TORQUE VALUES
Connecting Rod IN. MM
Piston pin fit (loose) 0.0003-0.0007 0.008-0.018
Side play between
flywheels
0.005-0.015 0.13-0.38
Connecting rod to
crankpin (loose)
0.0004-0.0017 0.0102-0.0432
Flywheel IN. MM
Runout
(flywheels at rim)
0.000-0.010 0.0-0.25
Runout
(shaft at flywheel)
0.000-0.002 0.0-0.05
End play 0.001-0.005 0.03-0.13
Sprocket Shaft
(Timken) Bearing
IN. MM
Cup fit in crankcase
(tight)
0.003-0.005 0.08-0.13
Cone fit on shaft (tight) 0.005-0.0015 0.013-0.038
Crankshaft (Roller)
Bearing
IN. MM
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038
Crankshaft runout 0.0-0.003 0.0-0.076
Bearing fit in
crankcase (tight)
0.0018-0.0021 0.046-0.053
Bearing inner race on
crankshaft (tight)
0.0009-0.0012 0.023-0.031
Item ft/in-lbs NM
Breather assembly bolts 90-120
in-lbs
10-14 Nm
Cam cover screws 125-155
in-lbs
14-18 Nm
Cam cover plate screws 20-30
in-lbs
2.3-3.4 Nm
Cam support plate screws 90-120
in-lbs
10-14 Nm
Bearing retainer plate
screws
20-30
in-lbs
2-3 Nm
Crank sprocket flange bolt
15 ft-lbs,
loosen one full
turn, 24 ft-lbs
20.3 Nm,
loosen one full
turn, 32.5 Nm
Primary cam sprocket
flange bolt
15 ft-lbs,
loosen one full
turn, 34 ft-lbs
20.3 Nm,
loosen one full
turn, 46.1 Nm
Crank position sensor
screw
90-120
in-lbs
10.2-13.6 Nm
Piston jet screws 25-35
in-lbs
2.8-4.0 Nm
Transmission housing to
crankcase bolts
15 ft-lbs,
30-35 ft-lbs
20 Nm,
41-48 Nm
Crankcase to front engine
mounting bracket bolts
33-38 ft-lbs 45-52 Nm
Crankcase bolts
10 ft-lbs,
15-19 ft-lbs
14 Nm,
20-26 Nm
Cylinder head bolts
7-9 ft-lbs,
12-14 ft-lbs
+ 90
o
turn
9-12 Nm,
16-19 Nm
+ 90
o
turn
Cylinder studs 10-20 ft-lbs 14-27 Nm
Engine oil drain plug 14-21 ft-lbs 19-28 Nm
Lifter cover screws 90-120
in-lbs
10-14 Nm
Oil pan screws 84-108
in-lbs
9-12 Nm
Oil filter 1/2-3/4 turn after gasket contact
Oil filter mount 130-150
in-lbs
15-17 Nm
Crankcase oil fittings/plugs 10-14 ft-lbs 14-19 Nm
Oil hose cover screws 84-108
in-lbs
10-12 Nm
Oil pressure sending unit 96-120
in-lbs
11-14 Nm
Rocker arm support
plate bolts
18-22 ft-lbs 24-30 Nm
Rocker cover bolts 15-18 ft-lbs 20-24 Nm
Rocker housing bolts 10-14 ft-lbs 14-19 Nm
Spark plugs 12-18 ft-lbs 16-24 Nm
Stator screws 30-40
in-lbs
4-5 Nm
Upper engine mounting
bracket:
To cylinder heads
To top stabilizer link
28-35 ft-lbs
18-22 ft-lbs
38-48 Nm
24-30 Nm
Engine sensor harness clip
screws to crankcase
25-35
in-lbs
2.8-4.0 Nm
Engine temperature
sensor
10-15 ft-lbs 14-20 Nm
Intake flange adapter
screws
96-144
in-lbs
10.9-16.3 Nm
Exhaust flange adapter
screws


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