2004 suzuki intruder 1500 motorcycle manual download

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SUZUKI INTRUDER 1500 LC BOTH WHEELS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 27-02-2011

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In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later. Front wheel removal : Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution : there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine. Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal

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SUZUKI GSX-R1000 SERVICE MANUAL

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Filed Under (Suzuki) by admin on 12-11-2010

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Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. 5. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft) ! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. ! Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

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Yamaha XVS 13AW Owner's Manual REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 06-01-2012

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GASOLINE IS HIGHLY FLAMMA- BLE: Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes

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Suzuki GSX-R 1000 AFR Tuner INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 20-02-2012

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The installation of the AFR Tuner should be done by experienced technicians only. Always disconnect the battery from the motorcycle before making any modification to the wiring harness. Remove the negative terminal from the battery before starting the installation work. The quality of the installation work greatly affects the reliability of the AFR Tuner and the motorcycle. Work precisely and very carefully when modifying the wiring harness of the vehicle. Always double check that the wire you are about to cut or tap into is the correct one. The ECM or the AFR Tuner can be destroyed by a faulty installation. 3.2. Installing the AFR Tuner to the wiring harness 3.2.1. Main cable The AFR Tuner connects to the motorcycle through its Main connector . Figure 2 shows the wiring diagram and the necessary modifications, which needs to be made when installing the unit into the fuel injection system of the motorcycle. Information about the ECM terminal numbers and wire colors for some popular motorcycles can be found in Chapter 6 . The best location for installing the AFR Tuner main unit is at the passenger seat area of the motorcycle mounted in the trunk space or on the subframe under the fairing, as this place provides protection from engine heat and the weather. Electrical contact between the metal casing of the AFR Tuner and the rear subframe must be prevented by using insulating material, such as the included self adhesive velcro strips. If necessary use some cable ties to secure the unit in place. The installation of the AFR Tuner into the wiring harness involves tapping into some wires and cutting others while connecting the two ends to the AFR Tuner. The harness modifications are best done near the ECM, since most of the wires can be found there. Part of the wiring modifications are related to connecting the AFR Tuner in-line between the ECM and the fuel injectors. In such cases when the motorcycle is equipped with primary and secondary injectors the AFR Tuner has to be installed on the primary injectors, which operate under all engine conditions. Correct grounding of the AFR Tuner is very important for electrical noise reduction. The above mentioned insulation of the metal case from the motorcycle frame is necessary for the same reason, which is to avoid the forming of a ground loop. An even more important requirement is the correct connection of the three ground wires of the AFR Tuner. As shown on Figure 2 , these three wires must be led out separately to the ECM and connected together at same point where the ECM ground wire is tapped into. This point should be as close to the ECM terminal as possible. For best quality of the electrical contacts all connections should be done by soldering and covering the exposed part of the wire with heat shrink tubing. For reliability reasons do not use clip on type wire taps

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2004 Vengeance MOTORCYCLE OWNERS MANUAL

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Filed Under (Vengeance) by admin on 21-11-2010

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Vengeance Warrior • Vengeance Raider • Vengeance Vertebreaker • Vengeance Striker • Vengeance Vendetta • Vengeance Vindicator Shifting Gears Starting off and changing gears requires coordination of the clutch and throttle and gearshift lever. If you don’t do things right, the amount of control you have over the bike is lessened. To start off, pull in the clutch, shift into first gear, roll on the throttle a little, and ease out the clutch. You will become familiar with the friction zone (that’s where the clutch begins to take hold and move the bike), and you add a bit more throttle. You don’t want to stall the engine, nor do you want to over-rev it. There’s a sweet spot in there; find it. Shift while traveling in a straight line. Shifting in a curve is not good practice, and something to be avoided. Become familiar with the sound of your engine, so you can tell when you should shift without looking at your instruments. When you downshift to a lower gear, you should (in one swift, smooth movement) be able to squeeze the clutch, rev the engine a little to let it catch the lower gear smoothly, and shift down. When you come to a stop in traffic, leave the bike in first gear with the clutch disengaged (just in case you want to accelerate out of there in a hurry). Who knows what may be coming up behind you. Braking Don’t ever forget: The front brake on your motorcycle can supply as much as 70 percent or more of your stopping power. The single most important thing you can learn about braking is to use that front brake every single time you want to slow down. Always apply both the front and the rear brakes at the same time. If necessary, apply them hard, but not so hard that you lock up either wheel. A locked wheel, as well as causing the bike to skid, results in downright inefficient braking. Turning When you are riding along the road, you lean a motorcycle into a turn. Learning to lean is an essential part of riding a motorcycle. It is a normal function of the bike when you are changing its path of travel – and quite different from turning the steering wheel of your car. To get the motorcycle to lean in a normal turn, press the handlebar in the direction of the turn and maintain slight pressure on that handlebar to take you smoothly through that particular turn. In other words: press right to go right; press left to go left. Your instincts to keep the motorcycle on a smooth path while keeping it from falling over usually take care of this without you even noticing it. (Demonstrate to yourself how a motorcycle moves by pressing a handlebar slightly while traveling in a straight line. The motorcycle will move in the direction of the handlebar you pushed.)

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

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Honda CG125 Owners Manual, and repair manual

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Filed Under (Honda) by admin on 11-12-2011

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The author of this manual has the conviction that the only way in which a meaningful and easy to follow text can be
written is first to do the work himself, under conditions similar to those found in the average household. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner. Unless specially mentioned, and therefore considered essential, Honda service tools have not been used. There is
invariably some alternative means of slackening or removing some vital component when service tools are not available and
isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs. In consequence, cross reference throughout this manual is both straightforward
and logical. When a reference is made ‘See Section 5.12′ it means Section 5, paragraph 12 in the same Chapter. If another
Chapter were meant, the text would read ‘See Chapter 2, Section 5.12′. All photographs are captioned with a Section/paragraph number to which they refer and are always relevant to the Chapter text adjacent. Figure numbers (usually line illustrations) appear in numerical order, within a given Chapter. Fig. 1.1 therefore refers o the first figure in Chapter 1. Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity.
We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us. No liability can be ccepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information give

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2003 SUZUKI SV 1000 Service Manual

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Filed Under (Suzuki) by admin on 26-02-2011

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections . 2. The section titles are listed in the GROUP INDEX . 3 . Holding the manual as shown at the right will allow you to find the first page of the section easily . 4. The contents are listed on the first page of each section to help you find the item and page you need . COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view . Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided . Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40 . If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart . BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result . Do not use any brake fluid taken from old or used or unsealed containers . Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil . GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only . WATER FOR MIXING Use distilled water only . Water other than distilled water can corrode and clog the aluminum radiator . ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze . Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator . LIQUID AMOUNT OF WATER/ENGINE COOLANT

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2003 – 2004 4Runner & Tundra, 2004 Camry, Highlander, Sienna & SolaraREPAIR MANUAL SUPPLEMENT LEV II EVAP SYSTEM CHECK

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Filed Under (Toyota Manuals) by admin on 24-10-2011

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this TSB provides detailed instructions for a new LEV II EVAP System Check function using the Diagnostic Tester. The LEV II System Check allows the Diagnostic Tester to display the fuel tank vapor pressure as the EVAP VSV and the CCV are operated in a specific six-step pattern. Problems with the EVAP system are quickly isolated by observing the change in vapor pressure during each step. Once the vehicle condition is corrected, the LEV II System Check can also be used to confirm the repair before the vehicle is returned to the customer. The inspection procedure using the LEV II System Check (LEV II SYS CHECK) is described in this bulletin. This function is available using a Diagnostic Tester with version 11.0a software (or newer

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Suzuki C-90 VL 1500LC Rear Lowering Kit INSTALLATION AND REMOVAL MANUAL

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Filed Under (Suzuki) by admin on 20-02-2012

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1. Decide how far you would like to lower your bike. Refer to the hole-index chart in these instructions to determine the proper mounting location holes for the drop you want to achieve. 2. Secure motorcycle to bike lift and raise the motorcycle so the rear wheel is unweighted. 3. For easiest access to the linkage remove the tool kit holder from the left side of the bike. 4. Loosen and remove the two self-locking nuts and flat washers from connecting arm bolts from the left side of the motorcycle. 5. Slide connecting arm bolts out (it may be necessary to push bushing back to the left side to allow bolt head to drop below frame. Reinstall in the same manner). Replace stock connecting arms with your new Baron connecting arms. The end with the single hole goes down and attaches to relay arm. The end with three holes goes up and attaches to the frame. Use the hole that lowers the rear your chosen amount. Reinstall bolts, washers and nuts. Torque the two connecting arm nuts to 35 foot-pounds (48 Nm). Remove motorcycle from lift. NOTE : We recommend that you set the shock spring preload to a higher setting, especially if the motorcycle will be used for carrying a passenger or heavy loads.

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