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The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit. This will give a good indication of the condition of the moving parts.Refer to the page listed in this section for removal and reinstallation instructions.Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure. NOTE: When loosen the rotor bolt, do not remove it. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head. Seat the pilot snugly. Rotate the cutter one or two turns. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit. They bear the following identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. 1.0 mm O.S. Oversize oil ring The following two types of oversize oil rings are available as op- 1.0 mm O.S. NOTE: When fitting the bearing cap to crank pin, be sure to discriminate between its two ends, I.D. 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. STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement. 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.
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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.NOTE: Fit the clamp to the bolt A.NOTE: Fit the new gaskets to the bolts A.Then tighten it 2 turns using the oil filter wrench. Also, apply engine oil onto the camshaft journal holders. 99000-25140: SUZUKI MOLY PASTE NOTE: The camshaft is identified by the embossed letters “F”. NOTE: Arrow marks are located to forward.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. The removed bearing must be replaced with a new one.If it is not within the specification, the shims must be changed. 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. 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. m (1 0 kgf m, 7.0 lb-ft) Fuel tank FUEL PUMP REMOVAL. 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. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw.
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Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-rings with new ones. INSPECTION Inspect the thermostat pellet for signs of cracking. NOTE: When installing the frame handle grip bolts, apply a small quan- tity of THREAD LOCK “1303”. 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. For USA ' 99000-25030: SUZUKI SUPER GREASE “A”. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. 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. The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork. NOTE: Apply grease to the oil seal 4 lip lightly before installing it. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A”. NOTE: Install the inner tube A until it seets to the flange part B of the steering stem upper bracket. If any de- fects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into swingarm cushion rod upper side bearing and check the play to move the spacer up and down. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below.SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester. NOTE: Make sure that the each spark plug cap and spark plug are con- nected properly.
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Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one. Check that the LED light immediately after turning the ignition switch on. Inspect the speed sensor and connection of couplers.If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones.Repair or replace. Excessive valve chatter 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height. Adjust or replace. Clean brake disc and brake pads. 4. Worn brake disc. Replace. Pass the battery -lead wire To spe dometer under the starter relay.Only one clip position is provided on the jet needle. If replace- ment becomes necessary the jet needle may only be replaced with an equivalent per orming replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best pos- sible performance and durability. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 ethanol, or less than 5 methanol with appropriate cosolvents and corro-. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 ethanol, or less than 5 methanol with appropriate cosolvents and corrosion. Connect the probe as shown to avoid opening of female ter- minal. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows.
These compensations are determined according to the signals from various sensors that detect the engine and driving conditions. SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form. NOTE: Warm up the engine before adjustment. 3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. Such disconnection will erase the memorized information in ECM memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble. R) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Blank Front cylinder IAP sensor signal (IAP. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler. Sensor voltage If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler. If OK, then check the ECT sensor lead wire continuity.
4) Disconnect the ECT sensor coupler. Sensor voltage If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler. STVA resistance: Approx. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler. If sound of the continuity is not heard from the tester, the cir- cuit condition is OK. IAP SENSOR INSPECTION The intake air pressure sensor is installed on the air intake pipe. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. NOTE: Be careful not to lift the fuel tank more than about 10 cm (3.94 in), or hoses will be twisted. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor. Gasoline is highly flammable and explosive.Blow the fuel mesh filter with compressed air. Use the new bushing to prevent fuel leakage. To avoid confusion, mark identifications when removing. If present, clean and check for presence of dirt in the fuel lines and fuel tank. The fuel injector can be checked without removing it from the throttle body. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
Example: TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.08 V STV fully open 1.20 V Idle. Dirt drawn into the engine will damage the internal engine parts. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 Fuel tank. The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve. Bolt The sealant side should face PAIR pipe side. To air cleaner box. With the bolt lightly contacted with the PAIR pipe, tighten the bolt. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 ethanol, or less than 5 methanol with appropriate cosolvents and corro-. Gasoline containing MTBE (Methyl Tertiary Butyl. The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve. Gasoline containing MTBE (Methyl Tertiary Butyl. Keep heat, spark and flame away. Clutch cable Handle switch RH harness Brake hose Outside High tension 0 mm. EVAP: Evaporative Emission ISC Valve: Idle Speed Control Valve (ISCV) Mileages are expressed in terms of kilome- ters, miles and months for your convenience. For details other than the following items, refer to the VL800 Service Manual. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months). If compressed air is applied to the. Wait until the engine are cool enough to touch. Valve clearance must be checked and adjusted when: (1) the valve mechanism is service, and (2) the camshafts are serviced. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks. The decision to overhaul the cylinder is often based on the results of a compression test.
Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. Go to Step 2. Make sure to check the color of coupler before install- ing. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position. Do not pinch the. Gasoline containing MTBE (Methyl Tertiary Butyl. The fresh air is drawn into the exhaust port through the PAIR control sole- noid valve and PAIR reed valve. January 30, 2021 Your Personal Finance Guide to Car Loans January 29, 2021 Getting Back in Shape: What Is Frame Straightening. January 29, 2021 What Is Classed as a Commercial Vehicle. January 28, 2021 The Revolution Will Drive Itself: The Dawning of the Age of Vehicular Automation January 28, 2021 Having Trouble Driving at Night. Here Is How You Can Stay Focused. January 27, 2021 6 Factors to Consider When Choosing a Car Repair Company January 26, 2021 How to Check Dealership Vehicle Stock Online January 25, 2021 Search Motor Era. Repair Manual DOWNLOADService Repair Manual DOWNLOAD. This is the most complete Service Repair.Repair Manual DOWNLOADService Repair Manual DOWNLOAD. This is the most complete Service Repair Manual for the 2001-2009 Suzuki VL800 Volusia Boulevard. C50 C50T ever compiled by mankind. This DOWNLOAD contains of high quality diagrams andThis is a must for the Do-It-Yourselfer. You will not be dissatisfied. Downloadable: YES. File Format: PDF. Language: English. Requirements: Adobe PDF Reader. Models Covers. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting, Steering, Seats, Clutch, Suspension, Locks, Brakes, Lubrication, Electrical, Frame, Fuel System, Exhaust, Battery, Wiring Diagram etc. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Suzuki Boulevard C50 Owners Manual.
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We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Suzuki Boulevard C50 can help maintain its resale value, save you money, and make it safer to ride. Take your entire manual with you on every journey. In doing so, no representation of affiliation, association or the like is intended, unless otherwise stated. Moreover, we are in fact owners of intellectual property, property that is a valuable asset to our business. Smula:( Tento web, stejne jako vetsina ostatnich, potrebuje ke spravne funkci JavaScript. Work instructions and other service informationUse engine coolant.Measure in voltage range.Measure in resistance range.Measure in current range.Measure in diode test range. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Suzuki Boulevard C50t Service Manual. To get started finding Suzuki Boulevard C50t Service Manual, you are right to find our website which has a comprehensive collection of manuals listed. This digitally delivered manual also covers 2009 DF100 model. Click here to download 2009-2013 Suzuki 90hp repair manual. It covers every aspect of maintenance, troubleshooting and repair. It is the same manual dealership mechanics use to fix your outboard engine. It contains step-by-step repair procedures, diagrams, illustrations and complete component specifications to help you complete the repair work successfully. They contain detailed pictures, diagrams, and step by step instructions that make fixing any motor problem easy to understand and work on. These manuals are crucial for any boat owner who wants to have the ability to fix their boat’s onboard motor.
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This book covers all major vehicle systems and shows you exactly how to carry out routine maintenance, restoration and servicing using easy to follow pictures, instructions, and diagrams, allowing you to save time and money by doing the work yourself. With over 150 million sold to date globally, Clymer is a recognized repair manual brand customers return to again and again. They are the ultimate DIY guide books for all powersport vehicles. As one of the most widely read repair books in the world, these manuals span the powersport industry. Clymer Manuals are available in both print and online editions under the Haynes and Clymer brands, and there is an extensive selection of repair books, written in both English and Spanish. Every manual is written from thorough hands-on experience based on a complete teardown, which is the step-by-step procedure for dismantling a vehicle or piece of equipment part-by-part. This is followed by the detailed rebuilding of the machine. Manual information is presented in a style that any DIYer can follow, even a beginner. Writing each manual takes 30 weeks, with authors working as teams to shorten the production time and to avoid fatigue during the difficult process. Hundreds of photographs accompany the step-by-step instructions. He wrote two more special builders manuals while doing his National Service in the RAF. The first Haynes Manual for the Austin Healey Frogeye Sprite was published in 1965. Based on the teardown and rebuild of that project vehicle and with extensive use of step-by-step photographs—a process that has not changed to this day—this manual set the standard for many generations to follow. This simple but important philosophy differentiates them from other repair manual companies. With over 50 years of experience in this market sector, they have deeply embedded processes, built-in expertise, and procedure-driven efficiencies which help give Haynes its unique identity.
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