1989-2004 Suzuki VS1400 Intruder service manual

Product Information

Table of Contents:

Chapter One: General Information

1. Manual Organization
   • Notes, cautions and warnings
   • Safety first
   • Service hints
2. Tools
   • Recommended tools
   • Special tools
3. Vehicle Identification
   • Identification number locations
   • Emission control information
4. Maintenance Procedures
   • Routine checks
   • General maintenance
   • Storage

Chapter Two: Troubleshooting

1. Operating Requirements
   • Starting the engine
   • Engine will not start
2. Engine Troubleshooting
   • Poor performance
   • Overheating
3. Electrical Troubleshooting
   • No electrical power
   • Poor headlight performance

Chapter Three: Lubrication, Maintenance and Tune-Up

1. Service Intervals
   • Routine checks
   • Specific intervals
2. Lubrication
   • Engine oil
   • Transmission oil
   • Battery
3. Tune-Up
   • Engine adjustments
   • Ignition system
   • Fuel system

Chapter Four: Engine Upper End

1. Engine Principles
   • Combustion process
   • Valve timing
2. Cylinder Head
   • Removal and installation
   • Inspection
3. Camshaft
   • Timing chain
   • Valve adjustment

Chapter Five: Engine Lower End

1. Oil Cooler
   • Removal and installation
   • Inspection
2. Crankshaft
   • Removal and installation
   • Inspection
3. Engine Break-In
   • Procedures
   • Recommendations

Chapter Six: Clutch and External Shift Mechanism

1. Clutch
   • Removal and installation
   • Inspection
2. Shift Mechanism
   • External linkages
   • Internal components

Chapter Seven: Transmission and Internal Shift Mechanism

1. Transmission
   • Removal and installation
   • Inspection
2. Shift Mechanism
   • Internal linkages
   • Adjustment procedures

Chapter Eight: Fuel, Emission Control and Exhaust Systems

1. Fuel System
   • Carburetor adjustments
   • Fuel tank maintenance
2. Emission Control System
   • Components and operation
   • Inspection procedures
3. Exhaust System
   • Muffler and pipes
   • Installation and inspection

Chapter Nine: Electrical System

1. Electrical Basics
   • Wiring diagrams
   • Electrical principles
2. Charging System
   • Battery maintenance
   • Alternator inspection
3. Ignition System
   • Spark plugs
   • Ignition coil
4. Lighting System
   • Headlights
   • Taillights

Chapter Ten: Front Suspension and Steering

1. Front Fork
   • Removal and installation
   • Inspection
2. Steering
   • Handlebar adjustments
   • Steering stem bearings

Chapter Eleven: Rear Suspension and Final Drive

1. Rear Suspension
   • Shock absorbers
   • Swing arm maintenance
2. Final Drive
   • Drive shaft
   • Differential inspection

Chapter Twelve: Brake System

1. Front Brakes
   • Caliper maintenance
   • Pad replacement
2. Rear Brakes
   • Drum brake inspection
   • Shoe replacement
3. Brake Lines
   • Inspection and replacement
   • Bleeding procedures

Chapter Thirteen: Body and Frame

1. Frame
   • Inspection and repair
   • Bodywork removal
2. Seats
   • Removal and installation
   • Inspection
3. Footpegs
   • Adjustment
   • Replacement

Index

Wiring Diagrams

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