Suzuki VLR1800 VLR1800K8 Boulevard C109R Intruder C1800R Workshop Repair Service Manual 2008 PDF - MSZKVLR08OPEK.zip
A full factory-style repair and service guide, complete with electrical wiring diagrams, covering the Suzuki VLR1800, BOULEVARD C109R, and INTRUDER C1800R motorcycles. It contains every technical detail needed to service, troubleshoot, fix, and rebuild these bikes at a professional mechanic's level.
Included in the Suzuki VLR1800, BOULEVARD C109R, INTRUDER C1800R workshop service and repair manual:
* 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