TABLE OF CONTENTS QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Torque specifications / Special tips / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic's tips / Ball bearing replacement / Seals / Riding safety / Storage CHAPTER TWO / TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Poor idle speed performance / Poor medium and high speed performance / Engine starting system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Engine leakdown test / Clutch / Transmission / Final drive / Handling / Frame noise / Brakes CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP Routine checks / Pre-ride inspection / Service intervals / Tires and wheels / Battery / Battery electrical cable connectors / Periodic lubrication / Periodic maintenance / Tune-up CHAPTER FOUR / ENGINE UPPER END Engine principles / Servicing engine in frame / Engine / Front cylinder head cover and camshaft / Rear cylinder head cover and camshaft / Camshaft / Rocker arm assemblies / Hydraulic tappets (valve lash adjusters) / Cylinder head and cylinder / Valves and valve components / Pistons and piston rings CHAPTER FIVE / ENGINE LOWER END Oil cooler / Primary drive gear and rear cylinder camshaft chain and sprocket / Secondary gear assembly / Crankcase / Engine break-in CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM External gearshift mechanism / Clutch / Clutch hydraulic system / Master cylinder / Slave cylinder / Bleeding the system CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission / Internal gearshift mechanism CHAPTER EIGHT / FUEL, EMISSION CONTROL AND EXHAUST SYSTEM Carburetor operation / Carburetor service / Carburetor assembly / Carburetor service / Carburetor adjustments / Throttle cable replacement / Fuel tank / Fuel shutoff valves / Fuel pump / Crankcase breather system (U.S. only) / Evaporative emission control system (California models only) / Exhaust system CHAPTER NINE / ELECTRICAL SYSTEM Basic information / Electrical connectors / Battery negative terminal / Charging system / Voltage regulator/rectifier / Alternator / Transistorized ignition system / Automatic compression release control and starter system / Electric starter / Starter clutch and gears / Starter relay / Lighting system / Switches / Electrical components / Fuses / Wiring diagrams CHAPTER TEN / FRONT SUSPENSION AND STEERING Front wheel / Front hub / Wheels / Tires / Tire changing / Tire repairs / Handlebar / Steering head and stem / Steering head bearing races / Front fork CHAPTER ELEVEN / REAR SUSPENSION AND FINAL DRIVE Rear wheel / Rear hub / Final drive unit, drive shaft and universal joint / Swing arm / Shock absorbers CHAPTER TWELVE / BRAKE SYSTEM Disc brakes / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Brake caliper disassembly/inspection/assembly (all models) / Rear master cylinder / Brake hose replacement / Brake disc / Bleeding the system / Rear brake pedal CHAPTER THIRTEEN / BODY AND FRAME Seats / Frame side covers / Frame head side covers / Footpegs / Sidestand / Front fender INDEX WIRING DIAGRAMS
MODELS COVERED
1987-2004 SUZUKI VS1400 Intruder