It also contains a troubleshooting guide, critical specifications, diagrams, schematics and photos to ensure the person performing the repairs completes the repair work successfully. Here's a list of topics found in a Suzuki four-wheeler repair manual actual subjects may differ depending on year and model :.
It can be downloaded to a computer, tablet or smart phone. You can get one from this website instantly! Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. This will give a good indication of the condition of the moving parts. EffilOil pressure: Above kPa 1. To insure proper performance and longevity of the clutch assemblies it is essential that the clutches engage smoothly and gradually.
Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train. Refer to the page listed in each section for removal and installation instructions. Engine removal is sequentially explained in the following steps. NOTE: Make sure to mark the aligning points of the gearshift arm and camshaft before removing the gearshift arm.
NOTE: Temporally tighten the nuts in this stage. The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten them to the specified torque. H Rear propeller shaft joint bolt: 23 N m 2. H Muffler connection bolt: 23 N m 2. If the cylinder head does not come off, lightly tap it using a plastic mallet.
If the cylinder does not come off, lightly tap it using a plastic mallet. Remove the cylinder gasket 3 and dowel pins. NOTE: Refer to chapter 4 when inspecting the secondary driven output shaft. Unlock the caulking as pointed and remove the transmis- sion output shaft nut using the special tool. Organize the parts in their respective groups i.
Measure the rocker arm bore with a caliper gauge. If the inside diameter is not within specification, replace the rocker arm with a new one. Standard: T ] Valve spring compressor Attachment Tweezers Remove the valve spring retainer and valve springs.
Remove the valve from the other side. If the runout exceeds the service limit, replace the valve with a new one. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. Rotate the cutter one or two turns. Check that no gasoline leaks though the valve seat. If leakage is found, correct the sealing surface. Page 73 U 3 Cam chain tensioner bolt: 13 N m 1. If the cams are worn to the service limit, replace the camshaft with new a one.
If the runout exceeds the service limit, replace the camshaft with a new one. If any clearance reading exceeds the service limit, replace both the piston and piston rings.
If the diameter exceeds the service limit, replace the piston with a new one. If the runout exceeds the service limit, replace the crankshaft with a new one. Page 85 To prevent damaging the oil seal lip from during installation, slide the lip using a 0.
Remove the special tool from the movable driven face assembly. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged. Only the oil pump unit is available as a replacement.
Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. Pay attention to the following points: NOTE Before installing the gears, apply engine oil to the inner surface of each gear and bushing.
Fit it to the side where the thrust is, as shown. The rounded side should be against the gear surface. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one as follows.
Page 98 Replace the removed oil seals with new ones. IT55LI Bearing installer set Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. For USA 4! H Crankcase bolt 8 mm: 22 N m 2. The spacer and side rails do not have a designated top and bottom. Make sure the guide 3 is inserted prop- erly or binding of the cam chain and guide may result.
If excessive play is noted, replace the bearing with a new one. Inspect the universal joint and outer surface of the bearing for scuffing, wear and damage. Rear output joint nut: N m NOTE: Do not disassemble the differential assembly. If any damages are found, replace the bearing with a new one. Information in this manual for Suzuki Vinson is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components.
Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work. The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions.
They may not show exactly the Suzuki Vinson in your possession. Adjustment and repair operations also include reference to wear limits for Suzuki Vinson In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
All work should be performed with great care and in a clean working area with adequate lighting. Please peruse and utilize this manual for Suzuki Vinson fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition. All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval.
The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type part number fastener as removed.
This Suzuki Vinson book outlines procedures for servicing and repairing vehicles using safe, effective methods. To maximise the life of your Suzuki Vinson Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual. Do not allow problems to develop.
Investigate unusual noises and changes in the riding characteristics of the Suzuki Vinson Rectify all problems as soon as possible immediately if safety related. Use only genuine Suzuki Vinson parts as listed in the parts catalogue. Follow the procedures in this manual carefully and completely.
Do not take short cuts. Keep complete records of all maintenance and repairs with dates and any new parts installed. Use only approved lubricants, as specified, in the manual of the Suzuki Vinson This manual for Suzuki Vinson has been issued to provide you with technical information regarding the design, function, disassembly, adjusting work and troubleshooting on the components and model of the Suzuki Vinson The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings.
All this information is intended to simplify any necessary repair work which can be performed on Suzuki Vinson This manual also contains information about adjusting work and valuable reference data for such adjustment values.
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