Suzuki 1500 Intruder, Boulevard C90 Repair Manual 1998-2007

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Item # M261  ISBN: 9781599691732




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This repair and service manual covers Suzuki Intruder LC 1500 (VL1500) 1998-2005, and Suzuki Boulevard C90/C90T (VL1500) 2006-2007.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Starting the engine | Engine will not start | Engine performance | Engine noises | Engine lubrication | Cylinder leakdown test | Clutch | Transmission | Electrical testing | Electrical systems | Steering and suspension | Shaft drive | Brake system

CHAPTER THREE: LUBRICATION and MAINTENANCE
Cylinder firing order | Engine rotation | Tune-up | Air filter | Compression test | Spark plugs | Engine oil and filter | Engine oil pressure test | Fuel filter (1998-2004 models) | Auto-decompression cable adjustment | Throttle cable free play | Engine idle speed | Fast idle speed (fuel injected models) | Throttle valve synchronization | Fuel line inspection | Emission control systems | Clutch | Shift pedal height | Control cable lubrication | Tires and wheels | Front suspension | Steering head | Rear suspension | Final drive | Brake system | General lubrication | Fasteners | Specifications

CHAPTER FOUR: ENGINE TOP END
Cylinder head side cap | Cylinder head cover | Hydraulic lifters | Camshafts | Cylinder and cylinder head assembly | Cam chains and rear chain guides | Valves and valve components | Piston and piston rings | Specifications

CHAPTER FIVE: ENGINE LOWER END
Engine | Alternator cover | Flywheel | Starter clutch and gears | Oil cooler | Oil pressure switch | Oil pressure relief valve | Oil pump gear | Oil pump | Crankcase | Crankshaft | Connecting rod | Engine break-in | Specifications

CHAPTER SIX: CLUTCH and PRIMARY DRIVE GEAR
Clutch hydraulic system | Clutch cover | Clutch | Clutch master cylinder | Clutch release cylinder | Clutch line | Primary drive gear | Specifications

CHAPTER SEVEN: TRANSMISSION, SHIFT MECHANISM and SECONDARY GEAR
Shift lever | Shift pedal | footrest | External shift mechanism | Internal shift mechanism | Transmission | Secondary gear cover | Secondary drive gear | Secondary driven gear assembly | Secondary gear alignment | Specifications

CHAPTER EIGHT: AIR, FUEL, EXHAUST and EMISSIONS SYSTEMS
Air filter housing | Fuel tank | Fuel pump | Fuel level sender | Fuel shutoff valve | Fuel inlet valve | Catch tank | Tank pressure control (TPC) valve | Carburetors Pilot screw | Throttle position (TP) sensor | Throttle cable replacement | Starter cable replacement (1998-2004 models) | Exhaust system | Evaporative emissions control system (California models) | Engine side box | PAIR system | Specifications

CHAPTER NINE: FUEL INJECTION SYSTEM
Fuel tank | Fuel pump | Fuel pump relay | Fuel level sender | Air filter housing | Throttle bodies | Fuel injectors | Throttle position (TP) sensor | Secondary throttle position (STP) sensor | Secondary throttle valve actuator (STVA) | Throttle cable replacement | Fast idle speed | Intake air pressure (IAP) sensor | Intake air temperature (IAT) sensor | Engine oil temperature (EOT) sensor | Heated oxygen (HO2) sensor (U.K., Europe and Australia models) | Tip over (TO) sensor | Exhaust system | Evaporative emissions control system (California models) | Engine side box | PAIR system | Diagnostic system | Specifications

CHAPTER TEN: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Battery | Charging system | Voltage regulator | rectifier | Stator | Ignition system | Signal generator | MAP sensor | Crankshaft position (CKP) sensor | Ignition coil | Igniter unit | Electronic control module (ECM) | Starting system | Starter | Starter relay | Sidestand switch | Neutral switch | Gear position (GP) sensor | Turn signal | sidestand relay | Auto-decompression solenoid | Auto-decompression relay | Lighting system | Horn | Speedometer (carbureted models) | Speedometer (fuel injected models) | Speed sensor | Switches | Fuses | Specifications

CHAPTER ELEVEN: WHEELS, HUBS and TIRES
Motorcycle stand | Brake rotor precaution | Wheel inspection | Wheel bearing inspection | Front wheel | Front hub | Rear wheel | Rear hub | Wheel balance | Tires | Specifications

CHAPTER TWELVE: FRONT SUSPENSION and STEERING
Front fork | Handlebar | Handlebar left grip replacement | Steering head and stem | Steering head bearing race replacement | Steering stem bearing replacement | Specifications

CHAPTER THIRTEEN: REAR SUSPENSION and FINAL DRIVE
Shock absorber | Suspension linkage | Swing arm | Bearing | race replacement | Final drive | Specifications

CHAPTER FOURTEEN: BRAKES
Brake service | Brake bleeding | Brake fluid draining | Brake pad inspection | Front brake caliper (1998-2001 models) | Front brake caliper (2002-on models) | Front brake caliper inspection (all models) | Front brake master cylinder | Rear brake caliper | Rear brake master cylinder | Brake hose replacement | Brake disc | Brake pedal | footrest | Specifications

CHAPTER FIFTEEN: BODY and FRAME
Trim clips | Seats | Steering head cover | Meter cover | Upper cover | Side cover | Sidestand | Tool box | Front fender | Rear fender | Specifications

COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Suzuki 1500 Intruder, Boulevard C90 Repair Manual 1998-2007