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1985-2009 SUZUKI INTRUDER/BOULEVARD MANUALS
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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
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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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