Suzuki Intruder VL1500 (1998-2009) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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SUZUKI INTRUDER VL1500 (1998-2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS

- English Service Manual / Repair Manual, Owners Manual and Wiring Diagrams, for motorcycles Suzuki Intruder VL1500 (1998-2009).

 
CONTENTS:

SERVICE MANUAL

Foreword
How To Use This Manual
- To Locate What You Are Looking For
- Component Parts And Work To Be Done
- Symbol
01 General Information
- Warning/Caution/Note
- General Precautions
- Suzuki Vl1500w ('98-Model)
- Serial Number Location
- Fuel And Oil Recommendation
- fuel
- engine oil
- gear oil (final drive gear oil)
- brake fluid
- front fork oil
- Break-In Procedures
- Cylinder Identification
- Information Labels
- Specifications
- Country And Area Codes
02 Periodic Maintenance
- Periodic Maintenance Chart
- Lubrication Points
- Maintenance And Tune-Up Procedures
- spark plugs
- air cleaner
- engine oil and oil filter
- fuel hose
- fuel strainer
- engine idle speed
- automatic de-compression cable
- throttle cable play
- carburetor synchronization
- evaporative emission control system (e-33 only)
- pair (air supply) system (e-33 only)
- clutch
- brakes
- final gear oil
- tire
- steering
- front fork
- rear suspension
- exhaust pipe bolts and muffler bolts
- chassis bolts and nuts
- Compression Pressure Check
- Oil Pressure Check
03 Engine
- Engine Components Removable With Engine In Place
- Engine Removal And Installation
- Engine Disassembly And Reassembly
- 3a Camshaft/Cylinder Head/Cylinder Head Cover
- camshaft/cylinder head/cylinder head cover removal
- camshaft/cylinder head/cylinder head cover servicing
- camshaft/cylinder head/cylinder head cover installation
- 3b Cylinder/Piston
- cylinder/piston removal
- cylinder/piston servicing
- cylinder/piston installation
- 3c Clutch
- clutch removal
- clutch release cylinder removal
- clutch/clutch release cylinder inspection
- clutch installation
- clutch release cylinder reassembly and installation
- 3d Starter System/Generator/Signal Generator
- starter torque limiter/generator/ signal generator removal
- starter torque limiter/generator/ signal generator inspection and service
- starter torque limiter/generator/ signal generator installation
- starter motor removal and disassembly
- starter motor inspection
- starter motor installation
- 3e Gearshift Linkage
- gearshift linkage removal
- gearshift linkage inspection and service
- gearshift linkage installation
- 3f Crankcase/Transmission/Crankshaft /Conrod
- transmission/crankshaft /conrod removal
- transmission inspection and service
- conrod/crankshaft inspection
- conrod-crank pin bearing inspection and service
- crankcase-crankshaft bearing inspection and service
- crankshaft thrust clearance adjustment
- transmission/crankshaft /conrod installation
- 3g Engine Lubrication System
- oil pump/oil sump filter
- oil pressure regulator
- oil pressure switch/oil cooler
- oil filter
- oil pressure
- oil jet
- engine lubrication system chart
- engine lubrication system
- cylinder head cooling system chart
- cylinder head cooling system
04 Shaft Drive
- Shaft Drive
- construction
- Secondary Bevel Gears
- construction
- secondary drive bevel gear removal
- secondary drive bevel gear disassembly
- secondary drive bevel gear removal
- inspection
- secondary gear shims adjustment
- secondary driven bevel gear installation
- secondary drive bevel gear reassembly
- secondary drive bevel gear installation
- Final Bevel Gears
- construction
- final gear case breather circuit
- final gear case removal
- final gear case disassembly
- inspection
- final gear shims adjustment
- final gear case reassembly
- final gear case installation
05 Fuel System
- Fuel System
- Fuel Tank
- removal
- remounting
- Fuel Pump
- removal
- inspection
- remounting
- Fuel Strainer
- removal
- inspection
- installation
- Fuel Level Gauge
- removal
- inspection
- installation
- Fuel-Vapor Separatori Fuel Shut-Off Valve
- removal
- inspection
- installation
- Fuel Tank Inlet Valve
- removal
- inspection
- installation
- Tpc (Tank Pressure Control) Valve
- removal
- inspection
- installation
- Carburetor
- construction
- specifications
- i.d. no. location
- diaphragm and piston operation
- slow system
- transient enrichment system
- main system
- starter (enricher) system
- float system
- removal
- disassembly
- carburetor cleaning
- carburetor inspection
- reassembly and remounting
- carburetor synchronization
06 Chassis
- Exterior Parts
- construction
- removal
- remounting
- Front Wheel
- construction
- removal
- inspection and disassembly
- reassembly and remounting
- Front Fork
- construction
- removal and disassembly
- inspection
- reassembly and remounting
- Steering
- construction
- removal and disassembly
- inspection and disassembly
- reassembly and remounting
- steering tension adjustment
- Rear Wheel
- construction
- removal
- disassembly
- inspection and disassembly
- reassembly and remounting
- Rear Suspension
- construction
- removal
- inspection and disassembly
- reassembly
- remounting
- Front Brake
- construction
- brake pad replacement
- brake fluid replacement
- brake caliper removal and disassembly
- brake caliper inspection
- brake caliper reassembly and remounting
- brake disc inspection
- master cylinder removal and disassembly
- master cylinder inspection
- master cylinder reassembly and remounting
- Rear Brake
- construction
- brake pad replacement
- brake fluid replacement
- brake caliper removal and disassembly
- brake caliper inspection
- brake caliper reassembly and remounting
- master cylinder removal and disassembly
- master cylinder inspection
- master cylinder reassembly and remounting
- Clutch Release Cylinder And Clutch Master Cylinder
- construction
- clutch fluid replacement
- clutch release cylinder removal and disassembly
- clutch release cylinder inspection
- clutch release cylinder reassembly and remounting
- clutch master cylinder removal and disassembly
- clutch master cylinder inspection
- clutch master cylinder reassembly and remounting
- Tires And Wheels
- tire removal
- inspection
- tire installation
07 Electrical System
- Cautions In Servicing
- Location Of Electrical Components
- Charging System
- description
- troubleshooting
- inspection
- Automatic De-Compression System, Starter System And Side-Stand Ignition Interlock System
- automatic de•compression system and starter system description
- side-stand/ignition interlock system description
- troubleshooting
- starter motor removal and disassembly
- starter motor inspection
- starter motor reassembly and installation
- starter relay inspection
- side-stand/ignition interlock system part inspection
- automatic de-compression relay inspection
- automatic de-compression solenoid inspection
- Ignition System (Digital Ignitor)
- description
- troubleshooting
- inspection
- Speedometer
- removal
- inspection
- Relays
- starter relay
- automatic de-compression relay
- turn signal side-stand relay
- Lamps
- headlight
- brake light/taillight
- turn signal lights
- Switches
- Battery
- specifications
- initial charging
- servicing
- recharging operation
08 Servicing Information
- Troubleshooting
- engine
- shaft drive
- carburetor
- chassis
- brakes
- electrical
- battery
- Wiring Diagram
- Wire Harness, Cable And Hose Routing
- wire harness routing
- cable routing
- fuel system hose routing
- front brake hose routing
- rear brake hose routing
- oil hose routing
- pair (air supply) system hose routing
- engine side box
- Upper Covers, Meter And Fuel Inlet Cover Set-Up
- Frame Head And Frame Cover Cushion
- Frame Cover Shield
- Brake Light/Taillight Set-Up
- Special Tools
- Tightening Torque
- engine
- secondary and final
- chassis
- tightening torque chart
- Service Data
09 Emission Control Information
- Emission Control Carburetor Components
- Evaporative Emission Control System
- Canister Hose Routing
- Evaporative Emission Control System Inspection
- Pair (Air Supply) System Diagram
- Pair (Air Supply) System Hose Routing
- Pair (Air Supply) System Inspection
10 Vl1500xiy('99, 2000 Models)
- Specifications
- Service Data
- Brakes
- Fuel Level Gauge
- Speedometer
- Wiring Diagram
- Front Brake Hose Routing
- Rear Brake Hose Routing
- Evaporative Emission Control System (California Model Only)
11 Vl 1500k1 ('01 Model)
- Specifications
- Service Data
- Engine Installation
- Wire Harness Routing
12 Vl1500k2('02 Model)
- Specifications
- Front Brake
- construction
- brake pad replacement
- brake fluid replacement
- brake caliper removal and disassembly
- brake caliper inspection
- brake disc inspection
- brake caliper reassembly and remounting
- Rear Brake
- construction
- brake pad replacement
- brake fluid replacement
- brake caliper removal and disassembly
- caliper inspection
- caliper reassembly and remounting
- wire harness routing
- front brake hose routing
- rear brake hose routing
- service data
13 Vl1500k3 ('03 Model)
- Specifications
- Service Data
- Wiring Diagram
14 Vl1500k4 ('04 Model)
- Specifications
- Service Data
- Periodic Maintenance Chart
- Wiring Diagram
15 Vl 1500k5 ('05-Model)
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- Specifications
- Periodic Maintenance Schedule
- Maintenance And Tune-Up Procedures
- Engine Components Removable With Engine In Place
- Engine Removal And Installation
- Engine Disassembly And Reassembly
- Engine Components Inspection And Servicing
- Precautions In Servicing
- Fi System Technical Features
- Fuel Delivery System
- Fi System Parts Location
- Fi System Wiring Diagram
- Ecm Terminal
- Self-Diagnosis Function
- Fail-Safe Function
- Fi System Troubleshooting
- Fuel System
- Throttle Body
- Sensors
- Exterior Parts
- Front Fork
- Location Of Electrical Components
- Charging System
- Automatic Decompression System/Starter System And Side-Stand Ignition Interlock System
- Ignition System
- Speedometer
- Relays
- Switches
- Battery
- Wiring Harness, Cable And Hose Routing
- Exterior Parts Installation
- Special Tools
- Tightening Torque
- Service Data
- Emission Control Systems
- Pair (Air Supply) System Inspection
- Pair (Air Supply) System Diagram
- Pair (Air Supply) System Hose Routing
- Evaporative Emission Control System Inspection(Only For E-33)
16 Vl1500k6 ('06-Model)
- Specifications
- Service Data
- Emission Control Systems
17 Vl1500k7/K8 (’07&’08-Model)
- Specifications
- Service Data
- Switches
- Front Brake Hose Routing
- Cable And Hose Routing
18 Vl1500k9 (’09-Model)
- Specifications
Wiring Diagram


OWNERS MANUAL

- Important
- Foreword
- The Sport Of Motorcycling
- Fuel And Oil Recommendation
- Controls, Equipment And Adjustments
- Break-In And Inspection Before Riding
- Riding Tips
- Accessory Use And Motorcycle Loading
- Inspection And Maintenance
- Troubleshooting
- Storage Procedure And Appearance Care
- Consumer Information