Suzuki VLR1800, BOULEVARD C109R, INTRUDER C1800R Repair Service Manual 2008
Complete service repair manual with Electrical Wiring Diagrams for Suzuki VLR1800, BOULEVARD C109R, INTRUDER C1800R Motorcycles, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki VLR1800, BOULEVARD C109R, INTRUDER C1800R Motorcycles workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Suzuki VLR1800 (VLR1800K8), BOULEVARD C109R, INTRUDER C1800R Service Manual 2008.pdf
PRODUCT DETAILS:
Total Pages: 623 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
99500-39360-01E VLR1800 SERVICE MANUAL...1
FOREWORD...2
TABLE OF CONTENTS...3
Precautions...5
Precautions...6
Precautions...6
Warning / Caution / Note...6
General Precautions...6
Precautions for Electrical Circuit Service...7
General Information...13
General Information...14
General Description...14
Symbols...14
Abbreviations...14
Vehicle Side View...15
Vehicle Identification Number...16
Fuel and Oil Recommendation...16
Engine Coolant Recommendation...17
BREAK-IN Procedures...17
Cylinder Identification...17
Country and Area Codes...18
Wire Color Symbols...18
Warning, Caution and Information Labels Location...19
Component Location...20
Electrical Components Location...20
Specifications...22
Specifications...22
Special Tools and Equipment...24
Special Tool...24
Maintenance and Lubrication...28
Precautions...28
Precautions for Maintenance...28
General Description...28
Recommended Fluids and Lubricants...28
Scheduled Maintenance...28
Periodic Maintenance Schedule Chart...28
Lubrication Points...29
Repair Instructions...30
Air Cleaner Element Replacement...30
Air Cleaner Element Inspection and Cleaning...30
Exhaust Pipe Bolt and Muffler Bolt Inspection...31
Exhaust Control Valve Inspection...31
Valve Clearance Inspection and Adjustment...32
Spark Plug Replacement...37
Spark Plug Inspection and Cleaning...37
Fuel Line Inspection...38
Evaporative Emission Control System Inspection (E-33 Only)...38
Engine Oil and Filter Replacement...38
Final Gear Oil Replacement...41
Throttle Cable Play Inspection and Adjustment...41
PAIR System Inspection...42
Throttle Valve Synchronization...42
Cooling System Inspection...42
Clutch Cable Play Inspection and Adjustment...44
Brake System Inspection...45
Tire Inspection...48
Steering System Inspection...49
Front Fork Inspection...49
Rear Suspension Inspection...49
Chassis Bolt and Nut Inspection...50
Compression Pressure Check...51
Oil Pressure Check...51
SDS Check...51
Specifications...52
Tightening Torque Specifications...52
Special Tools and Equipment...52
Recommended Service Material...52
Special Tool...52
Service Data...53
Specifications...53
Service Data...53
Tightening Torque List...60
Engine...65
Precautions...69
Precautions...69
Precautions for Engine...69
Engine General Information and Diagnosis...70
General Description...70
Injection Timing Description...70
Self-Diagnosis Function...71
Schematic and Routing Diagram...73
FI System Wiring Diagram...73
Terminal Alignment of ECM Coupler...74
Component Location...75
FI System Parts Location...75
Diagnostic Information and Procedures...77
Engine Symptom Diagnosis...77
Self-Diagnostic Procedures...81
Use of SDS Diagnosis Reset Procedures...83
Show Data When Trouble (Displaying Data at the Time of DTC)...84
SDS Check...86
DTC Table...89
Fail-Safe Function Table...91
FI System Troubleshooting...92
Malfunction Code and Defective Condition Table...93
DTC “C12” (P0335): CKP Sensor Circuit Malfunction...96
DTC “C13” (P1750-H/L) or “C17” (P0105-H/L): IAP Sensor Circuit Malfunction...99
DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction...107
DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction...116
DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction...121
DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction...126
DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction...133
DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction...133
DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction...137
DTC “C31” (P0705): GP Switch Circuit Malfunction...144
DTC “C32” (P0201), “C33” (P0202): Fuel Injector Circuit Malfunction...146
DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction...149
DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction...153
DTC “C42” (P1650): IG Switch Circuit Malfunction...155
DTC “C44” (P0156) or “C64” (P0130): O2 Sensor (O2S) Circuit Malfunction (For E-02, 19, 24, 33)...156
DTC “C46” (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction...160
DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction...173
DTC “C61” (P1656): PAIR Control Solenoid Valve Circuit Malfunction...176
DTC “C62” (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (For E-33)...179
Specifications...183
Service Data...183
Special Tools and Equipment...184
Special Tool...184
Emission Control Devices...186
Precautions...186
Precautions for Emission Control Devices...186
General Description...186
Fuel Injection System Description...186
Crankcase Emission Control System Description...187
Exhaust Emission Control System Description...188
Noise Emission Control System Description...189
Evaporative Emission Control System Diagram (Only for E-33)...190
Schematic and Routing Diagram...191
PAIR System Hose Routing Diagram...191
EVAP Canister Hose Routing Diagram (Only for E-33)...193
Repair Instructions...194
Oxygen Sensor (O2S) Removal and Installation...194
Heated Oxygen Sensor (O2S) Inspection...195
PAIR Reed Valve Removal and Installation...195
PAIR Control Solenoid Valve Removal and Installation...195
PAIR System Inspection...196
Crankcase Breather (PCV) Hose Inspection...197
Crankcase Breather (PCV) Hose Cover Removal and Installation...197
Crankcase Breather (PCV) Cover Inspection...198
Evaporative Emission Control System Removal and Installation (Only for E-33)...198
Evaporative Emission Control System Inspection (For E-33 only)...199
Specifications...201
Service Data...201
Tightening Torque Specifications...201
Special Tools and Equipment...201
Recommended Service Material...201
Special Tool...201
Engine Electrical Devices...202
Precautions...202
Precautions for Engine Electrical Device...202
Component Location...202
Engine Electrical Components Location...202
Diagnostic Information and Procedures...202
Engine Symptom Diagnosis...202
Repair Instructions...202
ECM Removal and Installation...202
CKP Sensor Inspection...202
CKP Sensor Removal and Installation...202
IAP Sensor Inspection...202
IAP Sensor Removal and Installation...203
TP Sensor Inspection...203
TP Sensor Removal and Installation...203
TP Sensor Adjustment...203
IAT Sensor Removal and Installation...204
ECT Sensor Removal and Installation...204
ECT Sensor Inspection...205
TO Sensor Removal and Installation...206
TO Sensor Inspection...206
STP Sensor Inspection...206
STP Sensor Adjustment...206
STP Sensor Removal and Installation...207
STV Actuator Inspection...208
STV Actuator Removal and Installation...208
ISC Valve Inspection...208
ISC Valve Removal and Installation...208
ISC Valve Preset and Opening Initialization...208
O2 Sensor Inspection...209
O2 Sensor Removal and Installation...209
GP Switch Inspection...209
GP Switch Removal and Installation...209
Specifications...210
Service Data...210
Tightening Torque Specifications...210
Special Tools and Equipment...211
Recommended Service Material...211
Special Tool...211
Engine Mechanical...212
Schematic and Routing Diagram...212
Camshaft and Sprocket Assembly Diagram...212
Throttle Cable Routing Diagram...213
Diagnostic Information and Procedures...214
Engine Mechanical Symptom Diagnosis...214
Compression Pressure Check...214
Repair Instructions...215
Engine Components Removable with the Engine in Place...215
Air Cleaner Element Removal and Installation...217
Air Cleaner Element Inspection and Cleaning...217
Air Cleaner Chamber Removal and Installation...217
Throttle Body Components...219
Throttle Body Construction...220
ISC Valve Removal and Installation...221
Throttle Body Removal and Installation...221
Throttle Body Disassembly and Assembly...223
Throttle Body Inspection and Cleaning...226
Throttle Valve Synchronization...227
ISC Valve Reset...229
Engine Assembly Removal...229
Engine Assembly Installation...234
Engine Top Side Disassembly...236
Engine Top Side Assembly...241
Valve Clearance Inspection and Adjustment...254
Cylinder Head Cover Inspection...254
Camshaft Inspection...254
Camshaft Sprocket and Automatic-decomp. Inspection...256
Cam Chain Tension No. 1 and No. 2 Adjuster Inspection...256
Cam Chain Guide No. 1, No. 2 and No. 3 Inspection...257
Cam Chain Tensioner No. 1 Inspection...257
Cylinder Head Cover Disassembly and Assembly...257
PAIR Reed Valve / PAIR Reed Valve Cover Inspection...258
Cylinder Head Disassembly and Assembly...258
Cylinder Head Related Parts Inspection...262
Valve Guide Replacement...264
Valve Seat Repair...265
Cam Chain Tensioner No. 2 Inspection...266
Cylinder Inspection...266
Piston Ring Removal and Installation...267
Piston and Piston Ring Inspection...268
Engine Bottom Side Disassembly...270
Engine Bottom Side Assembly...279
Conrod Removal and Installation...295
Conrod / Crankshaft Inspection...297
Conrod Crank Pin Bearing Inspection and Selection...297
Crankshaft Journal Bearing Inspection and Selection...299
Crankshaft Thrust Clearance Inspection and Selection...301
Balancer Driven Gear Disassembly and Assembly...303
Balancer Shaft Parts Inspection...305
Specifications...306
Service Data...306
Tightening Torque Specifications...308
Special Tools and Equipment...309
Recommended Service Material...309
Special Tool...310
Engine Lubrication System...313
Precautions...313
Precautions for Engine Oil...313
Schematic and Routing Diagram...313
Engine Lubrication System Chart Diagram...313
Diagnostic Information and Procedures...314
Engine Lubrication Symptom Diagnosis...314
Oil Pressure Check...314
Repair Instructions...315
Engine Oil and Filter Replacement...315
Engine Oil Level Inspection...315
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation...315
Oil Pressure Regulator / Oil Strainer Inspection...317
Oil Cooler Removal and Installation...318
Oil Pressure Switch Removal and Installation...319
Oil Pressure Switch Inspection...319
Oil Jet Removal and Installation...319
Oil Jet / Oil Gallery Jet Inspection...321
Oil Pump Removal and Installation...321
Oil Pump Inspection...322
Specifications...323
Service Data...323
Tightening Torque Specifications...323
Special Tools and Equipment...324
Recommended Service Material...324
Special Tool...324
Engine Cooling System...325
Precautions...325
Precautions for Engine Cooling System...325
Precautions for Engine Coolant...325
General Description...325
Engine Coolant Description...325
Schematic and Routing Diagram...326
Cooling Circuit Diagram...326
Water Hose Routing Diagram...327
Diagnostic Information and Procedures...328
Engine Cooling Symptom Diagnosis...328
Repair Instructions...328
Cooling Circuit Inspection...328
Radiator Cap Inspection...329
Radiator Inspection and Cleaning...329
Radiator / Cooling Fan Motor Removal and Installation...329
Water Hose Inspection...330
Water Hose Removal and Installation...331
Radiator Reservoir Tank Inspection...331
Radiator Reservoir Tank Removal and Installation...332
Cooling Fan Inspection...332
Cooling Fan Relay Inspection...333
ECT Sensor Removal and Installation...333
ECT Sensor Inspection...333
Thermostat Removal and Installation...333
Thermostat Inspection...334
Water pump Components...335
Water Pump Removal and Installation...336
Water Pump Disassembly and Assembly...337
Water Pump Related Parts Inspection...340
Specifications...341
Service Data...341
Tightening Torque Specifications...341
Special Tools and Equipment...342
Recommended Service Material...342
Special Tool...342
Fuel System...343
Precautions...343
Precautions for Fuel System...343
General Description...344
Fuel System Description...344
Diagnostic Information and Procedures...345
Fuel System Diagnosis...345
Repair Instructions...346
Fuel Pressure Inspection...346
Fuel Pump Inspection...346
Fuel Discharge Amount Inspection...347
Fuel Pump Relay Inspection...348
Fuel Hose Inspection...348
Fuel Level Gauge Inspection...348
Fuel Level Indicator Inspection...348
Fuel Level Indicator Switch (Thermistor) Inspection...348
Fuel Tank Construction...349
Fuel Tank Removal and Installation...350
Fuel Pump Components...351
Fuel Pump Assembly / Fuel Level Gauge Removal and Installation...352
Fuel Pump Disassembly and Assembly...353
Fuel Mesh Filter Inspection and Cleaning...354
Fuel Injector / Fuel Delivery Pipe Removal and Installation...355
Fuel Injector Inspection and Cleaning...355
Specifications...355
Service Data...355
Tightening Torque Specifications...355
Special Tools and Equipment...356
Recommended Service Material...356
Special Tool...356
Ignition System...357
Schematic and Routing Diagram...357
Ignition System Diagram...357
Ignition System Components Location...357
Diagnostic Information and Procedures...358
Ignition System Symptom Diagnosis...358
No Spark or Poor Spark...359
Repair Instructions...360
Ignition Coil / Plug Cap and Spark Plug Cap Removal and Installation...360
Ignition Coil Removal and Installation...361
Spark Plug Removal and Installation...362
Spark Plug Inspection and Cleaning...362
Ignition Coil / Plug Cap / Ignition Coil Inspection...362
CKP Sensor Inspection...365
CKP Sensor Removal and Installation...366
Engine Stop Switch Inspection...366
Ignition Switch Inspection...366
Ignition Switch Removal and Installation...366
Specifications...367
Service Data...367
Tightening Torque Specifications...367
Special Tools and Equipment...367
Special Tool...367
Starting System...368
Schematic and Routing Diagram...368
Starting System Diagram...368
Component Location...368
Starting System Components Location...368
Diagnostic Information and Procedures...368
Starting System Symptom Diagnosis...368
Starter Motor will not Run...369
Starter Motor Runs but Does not Crank the Engine...369
Repair Instructions...370
Starter Motor Components...370
Starter Motor Removal and Installation...371
Starter Motor Disassembly and Assembly...372
Starter Motor Inspection...373
Starter Relay Removal and Installation...374
Starter Relay Inspection...374
Turn Signal / Side-stand Relay Removal and Installation...375
Side-stand / Ignition Interlock System Parts Inspection...375
Starter Torque Limiter / Starter Clutch Removal and Installation...378
Starter Torque Limiter Inspection...379
Starter Clutch Inspection...380
Starter Button Inspection...380
Specifications...381
Service Data...381
Tightening Torque Specifications...381
Special Tools and Equipment...382
Recommended Service Material...382
Special Tool...382
Charging System...383
Schematic and Routing Diagram...383
Charging System Diagram...383
Component Location...383
Charging System Components Location...383
Diagnostic Information and Procedures...383
Charging System Symptom Diagnosis...383
Battery Runs Down Quickly...384
Repair Instructions...385
Battery Current Leakage Inspection...385
Regulated Voltage Inspection...385
Generator Inspection...386
Generator Removal and Installation...387
Regulator / Rectifier Inspection...389
Battery Components...390
Battery Charging...390
Battery / Battery Holder Removal and Installation...393
Battery Visual Inspection...394
Specifications...395
Service Data...395
Tightening Torque Specifications...395
Special Tools and Equipment...395
Recommended Service Material...395
Special Tool...395
Exhaust System...396
Precautions...396
Precautions for Exhaust System...396
General Description...396
Exhaust Control System Description...396
Exhaust Control System Operation...396
Repair Instructions...397
Exhaust Control System Construction...397
Exhaust System Components...398
EXCVA / EXCV Cable Removal and Installation...399
EXCVA Inspection...402
EXCVA Pulley / EXCV Cable Inspection...402
EXCVA Adjustment...402
Exhaust Pipe / Muffler Removal and Installation...404
Exhaust System Inspection...407
EXCV Inspection...407
Specifications...408
Service Data...408
Tightening Torque Specifications...408
Special Tools and Equipment...408
Recommended Service Material...408
Special Tool...408
Suspension...409
Precautions...410
Precautions...410
Precautions for Suspension...410
Suspension General Diagnosis...411
Diagnostic Information and Procedures...411
Suspension and Wheel Symptom Diagnosis...411
Front Suspension...412
Repair Instructions...412
Front Fork Components...412
Front Fork Removal and Installation...413
Front Fork Inspection...414
Front Fork Disassembly and Assembly...414
Front Fork Inspection...419
Front Fork Parts Inspection...419
Specifications...420
Service Data...420
Tightening Torque Specifications...420
Special Tools and Equipment...421
Recommended Service Material...421
Special Tool...421
Rear Suspension...422
Repair Instructions...422
Rear Suspension Components...422
Rear Suspension Assembly Construction...423
Rear Shock Absorber Removal and Installation...424
Rear Suspension Inspection...424
Rear Shock Absorber Inspection...425
Rear Suspension Adjustment...425
Rear Shock Absorber Disposal...425
Swingarm / Cushion Lever Removal and Installation...426
Cushion Lever / Cushion Rod Inspection...428
Cushion Lever / Cushion Rod Bearing Removal and Installation...429
Swingarm Related Parts Inspection...431
Swingarm Bearing Removal and Installation...432
Specifications...433
Service Data...433
Tightening Torque Specifications...433
Special Tools and Equipment...434
Recommended Service Material...434
Special Tool...434
Wheels and Tires...435
Precautions...435
Precautions for Wheel and Tire...435
Repair Instructions...436
Front Wheel Components...436
Front Wheel Assembly Construction...437
Front Wheel Assembly Removal and Installation...438
Front Wheel Related Parts Inspection...440
Front Wheel Dust Seal / Bearing Removal and Installation...441
Rear Wheel Components...443
Rear Wheel Assembly Construction...444
Rear Wheel Assembly Removal and Installation...445
Rear Wheel Related Parts Inspection...446
Rear Wheel Dust Seal / Bearing Removal and Installation...448
Tire Removal and Installation...449
Wheel / Tire / Air Valve Inspection and Cleaning...451
Air Valve Removal and Installation...451
Wheel Balance Check and Adjustment...452
Specifications...453
Service Data...453
Tightening Torque Specifications...453
Special Tools and Equipment...454
Recommended Service Material...454
Special Tool...454
Driveline / Axle...457
Precautions...458
Precautions...458
Precautions for Driveline / Axle...458
Drive Chain / Drive Train / Drive Shaft...459
Diagnostic Information and Procedures...459
Drive Chain and Sprocket Symptom Diagnosis...459
Repair Instructions...460
Secondary Gear Components...460
Secondary Gear Construction...461
Secondary Driven Gear Assembly Removal and Installation...461
Secondary Driven Gear Disassembly and Assembly...462
Secondary Driven Gear Related Parts Inspection...467
Secondary Gear Shim Inspection and Adjustment...468
Final Bevel Gear Components...470
Final Gear Construction...471
Final Gear Assembly Removal and Installation...471
Final Gear Disassembly and Assembly...472
Final Gear Parts Inspection...479
Universal Joint Removal and Installation...480
Universal Joint Inspection...481
Rear Wheel Dumper Removal and Installation...481
Wheel Dumper Inspection...482
Final Gear Shim Inspection and Adjustment...482
Specifications...486
Service Data...486
Tightening Torque Specifications...486
Special Tools and Equipment...487
Recommended Service Material...487
Special Tool...487
Brake...491
Precautions...492
Precautions...492
Precautions for Brake System...492
Brake Fluid Information...492
Brake Control System and Diagnosis...493
Schematic and Routing Diagram...493
Front Brake Hose Routing Diagram...493
Rear Brake Hose Routing Diagram...494
Diagnostic Information and Procedures...495
Brake Symptom Diagnosis...495
Repair Instructions...496
Brake Pedal Height Inspection and Adjustment...496
Front Brake Light Switch Inspection...496
Rear Brake Light Switch Inspection...496
Rear Brake Light Switch Inspection and Adjustment...496
Brake Fluid Level Check...497
Brake Hose Inspection...497
Air Bleeding from Brake Fluid Circuit...497
Brake Fluid Replacement...498
Front Brake Hose Removal and Installation...500
Rear Brake Hose Removal and Installation...500
Front Brake Master Cylinder Components...501
Front Brake Master Cylinder Assembly Removal and Installation...502
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...503
Front Brake Master Cylinder Parts Inspection...504
Rear Brake Master Cylinder Components...505
Rear Brake Master Cylinder Removal and Installation...506
Rear Brake Master Cylinder Disassembly and Assembly...508
Rear Brake Master Cylinder Parts Inspection...509
Specifications...510
Service Data...510
Tightening Torque Specifications...510
Special Tools and Equipment...511
Recommended Service Material...511
Special Tool...511
Front Brakes...512
Repair Instructions...512
Front Brake Components...512
Front Brake Pad Inspection...513
Front Brake Pad Replacement...513
Front Brake Caliper Removal and Installation...514
Front Brake Caliper Disassembly and Assembly...515
Front Brake Caliper Parts Inspection...518
Front Brake Disc Removal and Installation...519
Front Brake Disc Inspection...519
Specifications...520
Service Data...520
Tightening Torque Specifications...520
Special Tools and Equipment...521
Recommended Service Material...521
Special Tool...521
Rear Brakes...522
Repair Instructions...522
Rear Brake Components...522
Rear Brake Pad Inspection...523
Rear Brake Pad Replacement...523
Rear Brake Caliper Removal and Installation...524
Rear Brake Caliper Disassembly and Assembly...525
Rear Brake Caliper Parts Inspection...526
Rear Brake Disc Removal and Installation...528
Rear Brake Disc Inspection...528
Specifications...529
Service Data...529
Tightening Torque Specifications...529
Special Tools and Equipment...530
Recommended Service Material...530
Special Tool...530
Transmission / Transaxle...531
Precautions...532
Precautions...532
Precautions for Transmission / Transaxle...532
Manual Transmission...533
Diagnostic Information and Procedures...533
Manual Transmission Symptom Diagnosis...533
Repair Instructions...534
Transmission Components...534
Transmission Removal...535
Transmission Installation...536
Transmission Construction...539
Countershaft Gear / Driveshaft Gear Disassembly and Assembly...540
Transmission Related Parts Inspection...543
Gear Position (GP) Switch Inspection...544
Gear Position (GP) Switch Removal and Installation...544
Gearshift Lever Construction...545
Gearshift Lever Removal and Installation...546
Gearshift Lever Height Inspection and Adjustment...546
Gearshift Shaft / Gearshift Cam Plate Components...547
Gearshift Shaft / Gearshift Cam Plate Removal and Installation...547
Gearshift Linkage Inspection...550
Gearshift Shaft Oil Seal / Bearing Removal and Installation...551
Specifications...552
Service Data...552
Tightening Torque Specifications...552
Special Tools and Equipment...553
Recommended Service Material...553
Special Tool...553
Clutch...554
Precautions...554
Precautions for Clutch System...554
Schematic and Routing Diagram...554
Clutch Cable Routing Diagram...554
Diagnostic Information and Procedures...554
Clutch System Symptom Diagnosis...554
Repair Instructions...555
Clutch Lever Position Switch Inspection...555
Clutch Cable Removal and Installation...555
Clutch Components...556
Clutch Removal...557
Clutch Installation...559
Primary Driven Gear Removal and Installation...562
Clutch Parts Inspection...563
Specifications...565
Service Data...565
Tightening Torque Specifications...565
Special Tools and Equipment...566
Recommended Service Material...566
Special Tool...566
Steering...567
Precautions...568
Precautions...568
Precautions for Steering...568
Steering General Diagnosis...569
Diagnostic Information and Procedures...569
Steering Symptom Diagnosis...569
Steering / Handlebar...570
Repair Instructions...570
Handlebars Components...570
Handlebars Removal and Installation...571
Handlebars Inspection...573
Steering Components...573
Steering Removal and Installation...574
Steering Related Parts Inspection...576
Steering System Inspection...577
Steering Stem Bearing Removal and Installation...577
Steering Tension Adjustment...578
Specifications...578
Tightening Torque Specifications...578
Special Tools and Equipment...579
Recommended Service Material...579
Special Tool...579
Body and Accessories...581
Precautions...583
Precautions...583
Precautions for Electrical System...583
Component Location...583
Electrical Components Location...583
Wiring Systems...584
Schematic and Routing Diagram...584
Wiring Diagram...584
Wiring Harness Routing Diagram...590
Specifications...592
Service Data...592
Lighting Systems...593
Repair Instructions...593
Headlight Components...593
Headlight Removal and Installation...594
Headlight Bulb Replacement...594
Headlight Beam Adjustment...595
Headlight Relay Inspection...595
Rear Combination Light Components...596
Rear Combination Light Removal and Installation...596
License Plate Light Components...597
License Plate Light Removal and Installation...597
License Plate Light Bulb Replacement...598
Turn Signal Light Components...598
Front Turn Signal Light Removal and Installation...599
Rear Turn Signal Light Removal and Installation...599
Turn Signal Light Bulb Replacement...600
Turn Signal / Side-stand Relay Inspection...600
Turn Signal / Side-stand Relay Removal and Installation...600
Hazard Switch Inspection...600
Turn Signal Switch Inspection...601
Passing Light Switch Inspection...601
Dimmer Switch Inspection...602
Specifications...602
Service Data...602
Special Tools and Equipment...602
Special Tool...602
Combination Meter / Fuel Meter / Horn...603
General Description...603
Combination Meter System Description...603
Repair Instructions...604
Combination Meter Components...604
Combination Meter Removal and Installation...604
Combination Meter Disassembly and Assembly...604
Combination Meter Inspection...605
Engine Coolant Temperature Indicator Light Inspection...606
Engine Coolant Temperature Removal and Installation...606
Fuel Level Indicator Inspection...606
Fuel Level Indicator Switch (Thermistor) Inspection...607
Fuel Level Gauge Inspection...608
Speedometer Inspection...608
Speed Sensor Removal and Installation...608
Speed Sensor Inspection...609
Oil Pressure Indicator Inspection...610
Oil Pressure Switch Removal and Installation...610
Ignition Switch Inspection...610
Ignition Switch Removal and Installation...610
Horn Inspection...611
Horn Removal and Installation...611
Specifications...612
Service Data...612
Tightening Torque Specifications...612
Special Tools and Equipment...612
Recommended Service Material...612
Special Tool...612
Exterior Parts...613
Repair Instructions...613
Exterior Parts Construction...613
Fastener Removal and Installation...614
Exterior Parts Removal and Installation...615
Specifications...618
Tightening Torque Specifications...618
Special Tools and Equipment...618
Recommended Service Material...618
Body Structure...619
Repair Instructions...619
Body Frame Construction...619
Steering Lock Bracket Construction...620
Front Footrest Bracket Construction...620
Side-stand Construction...621
Side-stand Removal and Installation...621
Specifications...622
Tightening Torque Specifications...622
Special Tools and Equipment...622
Recommended Service Material...622
Suzuki VLR1800, BOULEVARD C109R, INTRUDER C1800R Repair Service Manual 2008
