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Suzuki intruder 800 service manual free download |
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Crankshaft journal bearing I. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one. Page 86 Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action.
If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both. Oil pressure switch: 14 N. The following steps require special attention or precautionary mea- sures should be taken.
NOTE: Apply engine oil to each running and sliding part before reas- sembling. Secondary gear case bolt Initial : 15 N. Cam chain tensioner bolt: 10 N. Then tighten it 2 turns using the oil filter wrench. NOTE: The convex side of the washer faces outside. Clutch sleeve hub nut: 60 N.
Page " Chain tensioner lock tool Cam chain tension adjuster mounting bolt: 10 N. Use a new gasket to prevent gas leakage. Page Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket.
Also, apply engine oil onto the camshaft journal holders. NOTE: Arrow marks are located to forward. Front Rear No. Use two pieces of shims. Shim 1 size table Part number Thickness A-0A0 0.
The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal.
NOTE: Refer to the following pages for the details of each step. The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. Page ! Final gear case bolt: 23 N. If it is not within the specification, the shims must be changed.
Pay attention to the following points. Use new O-ring and oil seat to prevent oil leakage. Use a new oil seal to prevent oil leakage. When installing the plate, fit the protrusion A of plate to the one of the bearing stopper grooves.
NOTE: Two kinds of plates are available to lock the stopper at the proper position. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. Keep heat, sparks, and flames away from gasoline. Be careful not to scratch the fuel tank. Clean the fuel filter with compressed air.
Also check the fuel valve for cracks. NOTE: mark A on the fuel level gauge forward. Face 10 N. Fuel level — The piston valve moves according to the negative pressure present on the downstream side of the venturi A.
The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through 1 pilot air jet 4 and 2 pilot air jet 5. This causes the piston valve 2 moves upward. The fuel in the float chamber 3 is metered by the main jet 4.
The metered fuel passes around main air bleed pipe 5, mixes with the air admitted through main air jet 6 to from an emulsion and emulsion fuel enters needle jet 7.
The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less.
Use a new O-ring to prevent fuel leakage. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw.
Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug. Make sure that the pressure build-up stops at 95— kPa 0. Page Do not allow the switch to touch the pan, or false read- ing will result. NOTE: The stamped mark on the oil seal faces outside. Be careful not to scratch the rear fender. Be careful not to scratch the rear fenders. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
Page Reassemble and remount the front wheel in the reverse order of removal and disassembly. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle. If any damages are found, replace the master cylinder with a new one. Be careful not to scratch the front fender. NOTE: Be careful not to damage the inner tube.
NOTE: Apply grease to the oil seal 4 lip lightly before installing it. NOTE: Hold the front fork upper cover to prevent it from falling. Page Apply grease to the O-ring and the final gear spline before install- ing the driven joint. Page Replace the brake shoes as a set, otherwise braking per- formance will be adversely affected. The Hall-Effect speed sensor circuitry is triggered by the teeth of the transmission mainshaft 4th gear. 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 seconds, after which time the recorded figure is zeroed. The odometer can display seven numbers to indicate a maximum of The trip odometer can display five numbers for a maximum of Reset Switch See Figure 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. The normal power-up sequence occurs before the diagnostic mode is entered. Any diagnostic codes set during this powerup sequence also will be stored. 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.
Silicone Brake Fluid D. Size Gap A 6R12 12 mm 0. Horn bracket acorn nut to rubber mount stud in-lbs 9. MM Shaft fit in bushing loose 0. Uploaded by mjtorres on May 13, Search icon An illustration of a magnifying glass. User icon An illustration of a person's head and chest. Sign up Log in. Web icon An illustration of a computer application window Wayback Machine Texts icon An illustration of an open book. Now, you dont have to rely on your mechanic for the simplest repair.
You can do it at the comfort of your garage. All pages are printable, so print off what you need and take it with you into the garage or workshop. This manual will never get dirty and rip as you can keep it safely on your PC and print the pages you need in matter of seconds.
Requirements: PDF Reader. S and U. The expert text gives complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide you through every step.
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