Suzuki Intruder 1978 Service Manual Download Page 95

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Summary of Contents for Intruder 1978

Page 1: ...arning symbol identifies special in structions or procedures which if not cor rectly followed could result in personal injury or loss of life This caution symbol identifies special in structions or pr...

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Page 3: ...a desired topic or procedure contained within this shop manual Bend the pages back until you match the de sired section above with the black tab on the right hand side of the table of contents for th...

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Page 5: ...Specifications Table of Contents Page General Specifications 1 2 Service Specifications 1 6 Torque Chart 1 8 Gear Ratio Chart 1 12 Engine Performance Curves 1 14 Port Dimensic ns 1 15 SPECIFICATIONS 1...

Page 6: ...EV CARBURETOR LEFT SIDE RIGHT SIDE Carburetor Make Mikuni Mikuni Carburetor Model VM 32 Econo Jet VM 32 Econo Jet Identification Marking L32 120 R32 121 Type of Carburetor Open Vent Open Vent Main Jet...

Page 7: ...g Wire Diameter 0 01 in 0 2 mm All Colors 0 197 in 5 0 mm Spring Rate 2 81b in 0 05 kg mm All Colors 561b in 1 0 kg mm Spring Compression 5 5 Ib 2 5kg 77 2 Ib 2 54 in 35 6 kg 64 5 mm Yellow 55 1 Ib 2...

Page 8: ...NVERTER RAMP WE IGHT COMBINATIONS USING RAMP WEIGHT IDENT IFIED C COMBINATION PART NO WEIGHT COMBINATION Weight Ramp Assy C 39152 3004 59_ 0 grams Weight Ramp Assy C Bolt Steel 6 x 20 mm Weight Ramp A...

Page 9: ...n 1 184 6 4 mm Width of Top Su rfaces 1 25 0 03 in 31 7 0 8 mm Thi ckness Top of belt to bottom of lug 0 53 0 03 in 13 5 0 8 mm Belt Taper Angle 300 BRAKE Minimum Brake Pad Thickness 1 16 in 1 58 mm G...

Page 10: ...ax 0 22 mm Bottom Ring Groove Clearance 0 008 in max 0 19 mm Piston Ring End Gap Top 0 008 0 016 in 0 2 0 4 mm Piston Ring End Gap Bottom 0 008 0 016 in 0 2 0 4 mm Piston Ski rt Clearance 0 002 0 004...

Page 11: ...el to Body Gasket Surface CHASSIS Converter Offset Distance 0 588 in 14 9 mm Converter Center Distance 12 in 305 mm Drive Chain Tension Self Adjusting Brake Lever Movement 3 4 in 19 mm Track Tension 3...

Page 12: ...to chaincase nut 2 35 ft Ib 4 84 kg m CHAINCASE AND JACKSHAFT Chaincase mounting nuts 4 18 ft Ib 2 5 kg m Chaincase cover mounting screVl s 6 70 in Ib 0 81 kg m Jackshaft bearing retainer to chassis r...

Page 13: ...t bolt 2 31 ft lb 4 28 kg m STEERING Handle holder bolt 1 35 ft Ib 4 84 kg m Steering arm to spindle bolt 2 30 ft Ib 4 15 kg m Steering column to tie rod nut 1 30 ft Ib 4 15 kg m Steering arms to tie...

Page 14: ...Ib 0 17 0 23 kg m Enrichener assy pal nut 1 Hand Tighten Speedometer cable nuts 1 Hand Tighten Throttle cable assy nuts 2 15 20 in Ib 0 17 0 23 kg m FAN C L SE AND AIR SHROUD Air shroud mounting scre...

Page 15: ...ter coil and pulser coil mounting screws 2 Use impact driver Lighting coil mounting screws 2 Use impact driver ELECTRICAL COl igniter mounting screws 2 60 in Ib 0 69 kg m Ignition coil mounting screw...

Page 16: ...n Gear Ratio 2 24 2 11 1 90 Speed 64 MPH 68 MPH 75 MPH Chain Pitch 64 64 66 Tensioner Spring Pink Green Red Gear Ratio 2 05 1 95 Speed 70 MPH 73 MPH Chain Pitch 66 66 Tensioner Spring Red Pink Gear Ra...

Page 17: ...ings Length 2 50 in 63 50 mm 2 50 in 63 50 mm 3 00 in 76 20 mm 3 00 in 76 20 mm 3 38 in 85 85 mm 3 38 in 85 85 mm 3 75 in 95 25 mm 3 75 in 95 25 mm Wire Dia 0 049 in 1 245 mm 0 055 in 1 397 mm 0 049 i...

Page 18: ...e Curves I V HORSEP WER I t TORQUE L V L V FUEL CONSUMPTION a a a a a a 1 a a a LCl ENG IN E R P M a a LCl CD a a a r a a LCl r 1 14 ENGINE PERFORMANCE CURVES 40 U a l 30 J I u w 20 d 0 0 I 10 1 60 0...

Page 19: ...in 0 mm C 1 1 32 3 mm 50 In 292 D 1 890 in mm E 1 189 in 48 0 mm F 3 807 in 30 2 mm G 0 516 in 96 7 mm H 19 13 1mm 061n 484 I 1 906 in mm J 0 516 in 48 4 mm K 0787 13 1 mm L In 20 0 mm 0 787 in 20 Omm...

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Page 21: ...Theory of Operation 2 24 Drive System Theo ry of Operation 2 26 Track Suspension and Steering System Theory of Operation 2 28 Two Cycle Engine Maintenance 2 29 Fuel System Maintenance 2 30 Ign ition S...

Page 22: ...1 r...

Page 23: ...52 exhaust Check ignition timing x 2 33 Replace drive belt be x x sure converter pulleys 2 42 are clean and dry Check drive converter x x and driven converter 2 37 alignment Check drive conVElrter x 3...

Page 24: ...ould be above center of sight glass but not higher than the top Shell XL100 10W 30 non foaming engine oil Level should be above center of sight glass but not higher than the top 2 4 LUBRICATION CHART...

Page 25: ...ed and forces the piston down This is called the power stroke 4 Exhaust After the power stroke the burned gases exit through the now open eX haust port and the cycle is ready to start again The piston...

Page 26: ...l to open the intake at about 1150 BTOC just after the transfer ports close However on a piston port engine this would require the intake to remain open unti l 1150 ATOC as well and all the crankcase...

Page 27: ...angu lar cross section are called flat rings The groove for th is type of ring has parallel walls Another type of ring has a wedge shaped cross section see Figure 2 3 This type of ring is called a key...

Page 28: ...spark plug in the combustion chamber The spark plug receives a timed surge of high voltage electricity to ign ite the mixture at the right instant If the ignition comes too soon the engine will try t...

Page 29: ...the com bustion chamber before ignition produced by the risi ng piston Another type of abnormal combustion is pre ignition If the combustion chamber becomes very hot or a fleck of carbon on the chamb...

Page 30: ...es The exhaust port opens and closes at about 800 to 900 BBDC The height of the port determines its t iming The higher the exhaust port the wider the exhaust angle 2 10 THEORY OF OPERATION The last bi...

Page 31: ...eces pressed together The crankwheels must be perfectly aligned on the crankpin See Figure 2 8 There is a specified side and radial clearance for the big end bearing of the connecting rod See Figure 2...

Page 32: ...on products can absorb in horsepower This extra heat is absorbed by the piston cyli nder walls and cylinder head The piston is cooled by the new fuel air mixture coming from the bottom by the new mixt...

Page 33: ...e engine causing it to reduce speed and power The carburetor controls the amount of fuel air mixture which reaches the engine See Figure 2 13 The fuel air ratio must be adjusted to meet the changing n...

Page 34: ...responds to the rider s needs by supplying fuel and air to the engine in the exact quantities demanded by speed and load Carburetor operation is based on the basic prin ciples of fluid dynamics These...

Page 35: ...n Under average conditions the pressure in the ventur i will be approximately 60 of the pres sure in the entry which is approximately the same as atmospheric pressure Metering System The carburetor co...

Page 36: ...n the ventur i would not be able to pull enough fuel up out of the bowl and into the air stream This would cause hard starting and lean mixture ratios If the fuel level is too high too much fuel is pu...

Page 37: ...way the greater air flow resistance and a richer mixture The slide cutaway provides for adjustment of the fuel air ratio as the transition is made from idle to the full venturi action of the carbureto...

Page 38: ...iameter of the jet is greater than the non tapered section of the needle The inside diameter of the needle jet used is 2 680 mm and the outside diameter of the needle is 2 512 mm Subtracting the diame...

Page 39: ...ed by passages in the carburetor body to a very small air jet in the front away from the engine end of the carbu retor Air flows in this jet through the passages and into the reservoir where it mixes...

Page 40: ...main jet determine the amount of fuel that should be de livered for the amount of air entering the engine This working relationship continues until approxi mately 3 4 throttle At this point the cross...

Page 41: ...s drilled in its body at the point where the air is introduced from the passage ways These holes allow fuel to be mixed with air before it enters the ventur i through the pilot outlet See Figure 2 30...

Page 42: ...r jet is drawn This tube has holes drilled in it similar to the pilot jet and air bleed needle jet These holes allow a small amount of air from the float chamber to be mixed with the fuel before it en...

Page 43: ...s an alternating current is induced in the coils mounted on the stator STATOR ASSEMBLY EMERGENCY STOP SWITCH WHITE COl IGNITER ENGINE CONNECTOR BLACK The COl igniter capacitor stores the charge genera...

Page 44: ...the stator pi ate The schematic shown in Figure 2 35 shows all of the components in the lighting system 2 24 THEORY OF OPERATION 1 The AC current from the lighting coils is routed through the voltage...

Page 45: ...E REGULATOR YELLOW RED BROWN YE L LOW BROWN YELLOW GRE EN HI ORANGE LO BRAKE LIGHT SWITCH L KEYSWITCH CONNECTIONS KEY SWITCH POSITIONS OFF RUN LIGHTS RUN I BROWN Z H s o J J UJ Z s o a en GREEN ORANGE...

Page 46: ...are as follows 1 Spring 2 We ights 3 Ramps 2 26 THEORY OF OPERATION 1 Roller 2 Spider Assembly 3 Spring 4 Movable Sheave 5 Weight Ramp 6 Drive Belt 7 Stationary Sheave Figure 2 37 The primary functio...

Page 47: ...ave as sembly is spread apart allowing the belt to ride on a smaller diameter of the flanges This change of flange diameter varies the drive ratio auto matical ly providing the most favorable ratio be...

Page 48: ...and spring compression For each in 25 4 mm the suspension moves up ward the shock absorber piston and spring move 1 in 25 4 mm See Figure 2 42 A 1 1 movement ratio resu Its in the following ad vantage...

Page 49: ...in clear for proper operation of the seal between the crankcase and gearcase or gearcase damage will result See Figure 2 43 To drain the engine gearcase 1 Remove the drain plug See Figure 2 43 2 Raise...

Page 50: ...in until the spring is coil bound Then back off each screw three complete turns initial adjustment Final adjustment is performed with the engine running turn each screw out equally until the engine i...

Page 51: ...that 1 Both throttle slides inside the carburetor bore opens fully and equally 2 With the throttle lever at idle there should be approximately 1 16 in 1 5 mm free play be tween the lever and housing...

Page 52: ...32 MAINTENANCE throttle lever on the handlebar is advanced_ See Fig ure 2 48 4 Loosen the locknuts on the oil pump cable and remove all the slack Adjustment is correct when the bellcra nk on the oil p...

Page 53: ...e magneto cover to the crankcase and shift the cover accordingly If the mark position is not corrected with this pro cedure replace the flywheel After the mark is corrected check the timing with a tim...

Page 54: ...pointer to the engine rather than the chassis so the pointer can move w ith the engine on its mounting system 2 Remove the spark plug from the RH cylinder and install a dial indicator into the RH cyli...

Page 55: ...d operation improper fuel to oil mixture or weak ignition system These plugs can usually be degreased and reinstalled See Figure 2 59 Figure 2 58 Figure 2 59 Burned or blistered insulator and badly er...

Page 56: ...creeping ahead and to assure proper aiming 4 Illuminate the headlight high beam The head light is properly aimed when the high beam is centered and aimed 2 in 51 mm below the reference mark on the wa...

Page 57: ...Alignment The converter alignment offset should be 0 588 in 14 9 mm as measured from the back face of the fixed sheave on the drive converter to the edge of the drive n converter movable sheave See F...

Page 58: ...ckshaft bearing retainer remember the number and placement of the shims between the retainer and the fram e The bearing retainer should be shimmed until the jackshaft centerline is 6 62 in 168 15 mm a...

Page 59: ...ment The converter alig nment offset shou Id be 0 588 in 14 9 mm as measured from the back face of the fixed sheave on the drive converter to the edge of th e driven converte r movable sheave See Fig...

Page 60: ...nt Gauge PIN 57001 3503 Correct converter center to center distance of 12 0 in 304 8 mm and converter offset distance 0 588 in 14 9 mm is obtained when alignment gauge PI N 57001 3503 is correctly ins...

Page 61: ...move the shims below the bearing reta iner b Position the bottom of the retainer parallel to the top of the chassis c Install U shaped sh ims as requ ired to fi ll the space between the bottom of reta...

Page 62: ...easuring dimens ions A and B as shown in Figure 2 77 Compare dimens ions A and B against Notes I and II 1 Distance A 2 Distance B 3 Alignment Gauge PI N 57001 3503 Figure 2 77 NOTE I Dimension A must...

Page 63: ...78 2 Rotate the movable half of the driven converter towards t he rear of the vehicle while pushing it tow ards the steering post Ass istance of another may be required to apply the brake whi le rotat...

Page 64: ...ONVERTER Any lubricant applied to the drive or driven converters will drastically change the shifting characteristics resulting in converter failure and reduced drive belt life Clean the drive and dri...

Page 65: ...es should be turned 1800 to use the unworn portion of the guide when one side is worn to within 0 12 in 3 0 mm of the tensioner arm pin See Figure 2 85 01 cD l 1 0 12 in 3 0 mm Figure 2 85 When both s...

Page 66: ...Gear Ratio 2 24 2 11 1 90 Speed 64 MPH 68 MPH 75 MPH Chain Pitch 64 64 66 Tensioner Spring Pink Green Red Gear Ratio 2 05 1 95 Speed 70 MPH 73 MPH Chain Pitch 66 66 Tensioner Spring Red Pink Gear Rati...

Page 67: ...rings Length Wire Dia 2 50 n 63 50 mm 0 049 n 1 245 mm 2 50 n 63 50 mm 0 055 n 1 397 mm 3 00 n 76 20 mm 0 049 n 1 245 mm 3 00 n 76 20 mm 0 055 n 1 397 mm 3 38 n 85 85 mm 0 049 n 1 245 mm 3 38 n 85 85...

Page 68: ...ere Figure 2 86 2 When the ski is para llel to the outside edge of the track check the steering handlebar for centering 3 If the handlebar requires centering loosen the lock jam nuts and turn the tie...

Page 69: ...andling Figure 2 90 Always adjust the preload tension of the front springs on each side of the suspension arm equal y Excessive tension of one spring can cause spring breakage or excessive wear to one...

Page 70: ...the wear strip to the top of the track should be 3 4 in 19 mm This dimension should be measured in the area directly below the rear suspension pivot arm bolt See Figure 2 92 1 3 4 in 19 mm 2 Rear Pivo...

Page 71: ...e Preparation for Storage 1 Thoroughly clean the snowmobile by hosing off all dirt and grime from the suspension and the engine compartment 2 Siphon the fuel from the fuel tank 2 50 STORAGE 3 Remove t...

Page 72: ...f sight gauge but not higher than the top 5 Remove the plugs masking tape or rags from the air intake silencer and muffler outlet 6 Using a suitable solvent clean the driven converter pulleys The conv...

Page 73: ...c b r...

Page 74: ...Stop Switch or Throttle Lever A ssembly 3 65 Head lamp 3 66 Key Sw itch 3 66 Speedometer 3 67 T achometer 3 67 Tail Lamp 3 67 Light Regulator Replacement 3 68 Throttle Cable and Oil Pump Cable 3 68 Br...

Page 75: ...gency stop switch in OFF position or malfunction ing 3 Spark plug s fouled oiled or damaged 4 Plug cap s damaged leaking or shorted 5 High tension wire s loose grounded or shorted 6 Defective CDI igni...

Page 76: ...check engine 9 Throttle slide valves not synchronized 1 Fouled or defective spark plug s 2 Obstruction inside of muffler 3 Defective CDI igniter Remedy 1 Tighten mounting bolt and nuts 2 Adjust the ca...

Page 77: ...e carbon buildup 7 Fan belt loose or broken 1 High tension lead wire shorting out 2 Fouled or incorrect spark pi ug heat ra nge too hot 3 Air leak between carburetor and cylinder 1 Carburetor incorrec...

Page 78: ...Incorrect spring 2 Incorrect weights 3 Dirty movable sheave Remedy 1 Replace ignition coil 2 Clean or replace filter 3 Remove obstruction re move pinched area from fuel line 4 Replace COl igniter 5 R...

Page 79: ...rcum ference below specifications 2 Thickness of belt on inside diameter exceeds specifica tions Condition 1 Incorrect belt excessive slippage 2 Too much throttle applied under heavy load excessive sl...

Page 80: ...ng when snowmobile is operated Condition 1 Incorrect chain tension 2 Cha in stretched beyond ad justable limit 1 Incorrect chain tension 2 Chain stretched beyond ad justable limit 3 Sprocket teeth wor...

Page 81: ...hets or hits on 1 Track tension is too loose 1 Set track tension and align body tunnel top ment Accelerated rail strip wear 1 Slide rail s bent 1 Straighten slide rail s or install new rails 2 Track i...

Page 82: ...light If lamp does not light in either the High or Low scale tests check teste r battery installation Check the clip leads for faulty connections If no faults can be found refer to the warranty state...

Page 83: ...setting If readings do not repeat output of the ignition system is erratic Indicator Lamp Does Not Light Unless Dial Is Turned Downscale From Specified Setting 3 10 ELECTRICAL TROUBLESHOOTING This in...

Page 84: ...tch circuits from the system See Figure 3 1 Separate wiring harness connector on the engine a Start the engine If the engine runs prop erly with the connector separated ignition components on the engi...

Page 85: ...ound wire between the engine con nector and the ignition coil is okay d If ohmmeter indicates open circ uit Xl or high resistance BROWN ground wire is defec tive Check BROWN wire connection at the rin...

Page 86: ...l Magneto Exciter Coil Out put ENG INE CON NECTOR EMERGENCY STOP SWITCH TEST 1 DIAL RANGE SETTI NG Low 25 TEST 2 TEST 3 DIA L DIAL RANGE SETTI NG RANGE SETTING High 50 Low 90 NOTE Refer to followi ng...

Page 87: ...blem TEST PROCEDURE NOTE After each test that lights the Indicator Lamp push the Reset button to turn the lamp off in preparati on for the next test 3 14 ELECTRICAL TROUBLESHOOTING MM1 CLI P 1 Set the...

Page 88: ...which is foul ed bridged or otherwise unfit for service Ir Consider the possibi lities that high heat vibration or moisture may be causing igniti on problems Retest injecting these factors into the t...

Page 89: ...URE 1 Set the toggle switch to the High range Set the tester dial to 50 3 16 ELECTRICAL TROUBLESHOOTING 2 Turn over the engine while observing the In dicator Lamp on the tester a If the lamp lights pu...

Page 90: ...lywheel assembly and repeat Test 2 replace magneto exciter coil Repeat Test 3 Proceed to Test 3 TEST 2 Magneto Exciter Coil Ou tput Proceed to Test 3 No Lamp or Low Inconsistent Reading Lamp Lights at...

Page 91: ...ngine ground 3 18 ELECTRICAL TROUBLESHOOTING o KEY SWITCH TEST PROCEDURE 1 Set the toggle switch to the Low range Set the tester dial to 90 2 Turn over the engine while observing the In dicator Lamp o...

Page 92: ...and repair if possible or replace magneto pusler coil Repeat Test 3 Replace flywheel assembly Proceed to Test ttA and repeat Test 3 No Lamp or Low Inconsistent Reading 1 n Lamp Lights at Specified Va...

Page 93: ...wire terminal in the COl igniter half of the three wire connector 5 Connect the load coil between the tester P red and N yellow lead wires 3 20 ELECTRICAL TROUBLESHOOTING TEST PROCEDURE 1 Set the togg...

Page 94: ...___ L__________________ No Output replace COl Igniter and repeat Test 1 Replace ignition coil and repeat Test 1 No Lamp or Low Inconsistent Reading n Lamp Lights at Specified Value 1 1 STANDARD VALUE...

Page 95: ...empt to remove using a hammer The flywheel or crankshaft will be damaged NOTE Exercise care to prevent an electrical shock from the COl igniter Handle the COl igniter care fully If you should drop it...

Page 96: ...NCY STOP SWITCH PARTS TO BE MEASURED RESISTANCE GRAY PRIMARY WINDING C GROUND D 0 37 O 20 10 With spark plug caps removed PART TO BE PULSER MEASURED EXCITER COIL OHMMETER LEADS RED WHITE CONNECTED BRO...

Page 97: ...plug is shorted resista nce between electrodes should be 1 M n or more 7 Wrong wire connections 1 Defective exciter coil 2 Defective pulser coil 3 Improper timing 4 Defective CDI igniter 5 Shorted sp...

Page 98: ...pen circu it co Re place the switch if the needle moves off of in finity 00 4 Turn the key switch to OFF position Meter should now indicate closed circuit 0 Replace the switch if the needle does not m...

Page 99: ...hm scale X100 Connect one ohmmeter lead to one terminal in the stop switch half of the connector Connect the other lead to the other terminal in the stop switch half of the connector See Figure 3 7 3...

Page 100: ...ITCH CIRCUIT COMPLETED POSITIONS BEWoJEEN CONTACTS MARKED OFF G M RUN LIGHTS S l RUN NON E BLUE BROWN BRAKE LIGHT BLAC K COMMON YEllOW TAIL LIGHT BROWN INPUT GR EEN HI DIMMER SYliTCH ORANG E La GR EEN...

Page 101: ...y moving the ohmmeter lead from the high beam term inal to the low beam termina l If the needle i ndicates infinity 00 or more than 2 ohms replace the bulb 3 28 ELECTR ICAL SYSTEM CHECKS g If the head...

Page 102: ...or replaced Stop and Tail Light 1 Check stop tail light bulb before testing and make sure it is making a good con nection in the socket 2 Discon nect t he tail light connector from the main harness 3...

Page 103: ...located in the hand lebar brake lever assembly 1 Disconnect the brake switch from the ma in harness 2 Set the ohmmeter to low ohms Xl Connect an ohmmeter lead to the yellow wire terminal in the brake...

Page 104: ...ECTION PLATE NOZZLES FL YWHEEL I RECOILSPRING ROPE REEL Ir STATOR EXCITER LIGHT CYLINDERS PLATE AND PULSER COILS L EAD PISTONS RINGS WIRES WRIST PINS AND PIN BEARINGS Removal installation disassembly...

Page 105: ...OIL LINE TO PUMP OIL PUMP CONTROL AIR SI LENCER CARBU RETOR IMPULSE LINE RE MOV E THE ENGINE I Removal installation disassembly or assembly requires use of special tool s RECOI L STARTER HANDLE NOTE...

Page 106: ...PAW LS PU L L EY INJECTION CUP NOZZLES r I RECOI L SPR ING CYLINDERS ROPE RE EL PISTONS RINGS WRIST PINS AND BEARINGS STATOR PLATE LEAD OIL PUMP CRANKCASE WIRES GEAR CASE CRANKSHAFT GEARS Removal inst...

Page 107: ...e out of exhaust outlet boot Installation Install the muffler by reversing the removal pro cedure Make sure the insulation washers are properly positioned on each side of the muffler brackets See Figu...

Page 108: ...ing is installed on the top and the short spring on the bottom Carburetor This engine is equipped w ith twin Mikuni VM32 econo jet carburetors Removal Remove the air intake silencer Remove the carbure...

Page 109: ...ng screw and spring Cleaning VM32 Carburetor Thoroughly clean all parts w ith a mild solvent or fuel oil mixture Inspect all drilled holes openings and f uel passages in the body Blow compressed air t...

Page 110: ...rt the end of the cab le thro ugh the hole in the throttle slide valve slot 6 While keeping the spring compressed release the throttle valve and install the spring seat plate Then release the spring 7...

Page 111: ...Spring 7 Pilot Air Screw 8 Float Pin 9 Float Chamber Gasket 10 Pilot Jet 11 Baffle 12 Holder Washer 13 Carb Needle Holder 14 Holder O Ring 15 Float Arm 16 Float Retainer 17 Float 18 Main Jet 19 Float...

Page 112: ...e ha lf throttle opening 3 Jet Needle and Needle Jet one eighth to seven eighths throttle opening 4 Main Jet one quarter to full throttle opening 5 Econo Jet one half to full throttle opening Tuning e...

Page 113: ...n throttle the main jet sup plies approximately 70 of the engines fuel re quirements whi le the econo jet supplies 30 The econo jet stops feeding fuel below 1 2 throttle or 5000 RPM due to the red uct...

Page 114: ...agm assembly 7 Install cap onto diaphragm assembly Be sure alignment tabs on cap diaphragm assembly body A gasket and body B are indexed properly 8 Install eight retaining screws and t ig hten in a cr...

Page 115: ...k to disconnect the two exhaust springs 10 Remove the drive converter mounting bolt and lockwasher Install the drive converter puller bolt tool No 57001 3502 and screw in to re move the drive converte...

Page 116: ...spring Examine the starter rope for excessive wear or frayed cond ition Disassembly 1 Release recoil spring tens ion by removing handle from starter rope and allowing recoil reel to spi n slowly 2 Rem...

Page 117: ...om accidently disengaging Spring should remain in the recoil case When in stalling a new recoil spring attach hook in recoil spring to recoil case Reassembly 1 Thoroughly clean all parts removed prior...

Page 118: ...olt 6 Return Spring 7 Pawl 8 Recoil Ree l 9 Slide Plate B 10 Sl ide Plate A 11 Washer 12 Bushing 13 Return Spring 14 Spring 15 Friction Plate 16 Washer 17 Washer 18 Nut 19 Recoil Spring 20 Sta rter Ro...

Page 119: ...ler special tool No T56019 01 to the flywheel with the three fly wheel puller bolts No 11 OG0630 The starter pulley and fan drive pulley are still in position under the flywheel pul ler Pull the flyw...

Page 120: ...rankcase See Figure 3 36 Figure 3 36 jJ 115 0 1314 2 4 8 Remove the stator plate See Figure 3 37 Figure 3 37 Disassembly Refer to Figure 3 38 for disassembly sequence of magneto components 1 Flywhe 31...

Page 121: ...assembly NOTE Install fan drive pulley with machined shoulder toward flywheel 4 Reinstall starter pulley and fan drive pulley onto flywheel Secure with the three bolts 5 Assemble flywheel to the crank...

Page 122: ...n each side of exhaust air shroud Secure using hardware previously removed Torque ex haust manifold mounting nuts 8 to 10ft Ib 1 11 to 1 38 kg m 2 Position a new gasket between cylinder and in take ai...

Page 123: ...half to maintain proper belt alignment 1 Spacers 2 Pulley Halves Figure 3 45 4 Using a heat gun or propane torch heat aluminum fan case allowing bearings to be removed from fan case IWARNINGI Do not c...

Page 124: ...ulley half to fan shaft Assemble same number of pulley spacer washers to shaft as previously removed and attach rema Inlng pulley half to shaft Secure pulley halves to shaft using washer and nut Torqu...

Page 125: ...cyl inder head in solvent and blow dry using compressed air 4 Place a straight edge across the gasket surface of the head to detect any warpage Measure in several spots If slight distortion is present...

Page 126: ...l for excessive scoring 4 Using an dial bore gauge check the cyl inder bore for wear If the cylinder diameter exceeds the dimension shown under Service Limit in Figure 3 52 replace the cylinder NOTE T...

Page 127: ...mm above the bottom of the piston skirt See Figure 3 53 If the dif ference in the measurements obtained is less than 0 002 in 0 05 mm or more than 0 004 in 0 10 mm replace the piston If the piston ski...

Page 128: ...feeler gauge in the opening between the ends of the piston ring See Figure 3 57 If maximum ring gap exceeds the Service Limits when measured at the top and the bottom of the cylinder bore re pi ace t...

Page 129: ...ure 3 59 NOTE Install the pistons w ith the letter E and the arrow mark to the exhaust side front of the en gine See Figure 3 60 4 Install new cylinder base gaskets on the crankcase 5 Lubricate the cy...

Page 130: ...necessary to use premixed fuel 40 to 1 Use a one gallon can with a hose con nected to the inlet of the fue l pump Disconnect the oil pump output lines at oil pump Install separate oil tubes to each o...

Page 131: ...with the cover and if so remove it so it will not become lost See Figure 3 67 3 58 01 L INJECTION SYSTEM Figure 3 67 5 Remove the idler gear Take care not to lose the spacer in back of the gear See F...

Page 132: ...ir on the check valve High pressure air will damage the valve which will result in engine failure o DD 1 Spring 2 Steel Ball Figure 3 71 Check the gears bearings and seals for wear or damage and repla...

Page 133: ...secure with two bolts Be sure to install new seal washers on the mounting bolts to prevent gearcase oil leakage Bleed oil pump by removing bleed bolt and holding control lever in full open position H...

Page 134: ...4 SHIM NUMBER DESCRIPTION No Thickness Part No 1 00787 inches 0 2 0 015 mm 92025 3007 2 02362 inches 0 6 0 030 mm 92025 3008 3 03937 inches 1 0 0 040 mm 92025 3009 4 05512 inches 1 4 0 050 mm 92025 30...

Page 135: ...plate and the crankcase boss to assure proper indexing during reassembly See Figure 3 78 1 Scribe Mark Figure 3 78 4 Remove the screws securing stator plate to the crankcase and remove the stator pla...

Page 136: ...nce is 0 0008 0 001 in 0 02 0 03 mm if the radial clearance exceeds these dimensions re place the crankshaft assembly Figure 3 81 4 If the outer bearings seals or oil pump drive gear require replaceme...

Page 137: ...inch 0 9t 0 04 mm 0 0393 0 0016 inch 1 0t 0 04 mm 0 0472 0 0020 inch 1 2t 0 05 mm Installation 1 Shim Figure 3 84 Part No 92025 3001 92025 3002 92025 3003 92025 3004 92025 3005 1 Place the crankshaft...

Page 138: ...te 4 Brake Lever 9 Plate Screw 5 Pin Washer 10 Brake Light Switch Figure 3 88 5 Remove screw securi ng brake case plate to the case and remove the plate Either switch can now be slid out of the case a...

Page 139: ...and springs The headlamp assembly can now be removed from the hood Disassemble headlamp as ill ustrated in Figure 3 90 3 66 KEY SWITCH 1 Headlamp Assembly 2 Headlamp Lens 3 Headlamp Bulb 4 Upper Adjus...

Page 140: ...eedometer cable and hand tighten See Figure 3 92 Tachometer Removal 1 Remove the light bulb assembly from the tach ometer and disconnect wires from the tach ometer 2 Remove the tachometer bracket and...

Page 141: ...ottle slide valve and separ ate the throttle cable from the throttle slide valve 1 Mixing Body Top Assembly 2 Throttle Slide Valve Assembly 3 Spring 4 Throttle Spri ng Seat Plate Figure 3 95 4 Loosen...

Page 142: ...en release the spring 8 Install the throttle slide valve into the carbure tor so the slot in the throttle valve mates with the locating pin in the throttle valve bore In stall the mixing body top asse...

Page 143: ...ure 3 98 4 Install the second locknut on the end of the brake cable Install the brake cable tip to the retainer and connect the return spring For brake cable adjustment see Section 2 Enrichener Cable...

Page 144: ...o of the cover suddenly as the cover can pop up and cause personal injury 1 With a firm grip on the cover to prevent the spri ng from pushi ng the cover off remove the bolts that secure the cover on t...

Page 145: ...le sheave and replace any part which shows signs of wear Measure the thick ness of the spacers with a micrometer they should be 0 032 0 004 in 0 8 0 1 mm if they measure 0 016 in 0 4 mm or less re pla...

Page 146: ...ll the spider NOTE Due to the indexing of the splines the arrows may not align perfect Align as close as possible 7 Apply NEVER SEEZ to the oil groove area fill ing the grooves and the bottom surface...

Page 147: ...g 2 Bolt 9 Spider 3 Special Washer 10 Wear Guide 4 Flanged Bolt 11 Split Washer 5 Cover Assembly 12 Movable Sheave Assembly 6 Bushing 13 Bushing 7 Sleeve 14 Aluminum Bolt Figure 3 109 3 74 DRIVE CONVE...

Page 148: ...riven converter remove left side aluminum trim from lower pan by removing mounting hardware See Figure 3 111 Lower pan is notched to allow driven converter removal Remove the large bolt that retains t...

Page 149: ...jackshaft if the difference be tween the readings is 0 02 in 0 5 mm or greater replace the bushing See Figures 3 115 and 3 116 3 76 DRIVEN CONVERTER Figure 3 115 Figure 3 116 5 Place the shaft end of...

Page 150: ...kwise from the oval protrusion when viewing from the splined end Note Check to be sure the parts have no holes or dents 4 Insert the spring Place tang of spring into hole marked B in the fixed sheave...

Page 151: ...re tainer ring with the sharp or square edges out and make sure it seats completely into the groove 6 Install the coupling Be sure to align the arrow on the coupling with the arrows on the as sembly I...

Page 152: ...4 Figure 3 121 DRIVEN CONVERTER 3 79...

Page 153: ...jackshaft along with chaincase Do not lose the woodruff key that fastens the brake hub to the jackshaft 3 80 CHAINCASE 1 Tensioner Spring 2 Chain 3 Top Sprocket 4 Bottom Sprocket 5 Chaincase Mounting...

Page 154: ...nstall brake pad back up plate and movable brake pad into chaincase and install fixed caliper and brake cable bracket with bolts and nuts 4 Insert push pins into brake housing and install spring guide...

Page 155: ...to Section 2 Brake Caliper Removal See Figure 3 125 1 Remove brake return spring Remove brake cable from clevis retainer Remove brake cable from brake cable bracket 2 Remove nut washer brake lever spr...

Page 156: ...ial Nut 19 Retainer Bushing 4 Pad Back up Plate 12 Brake Disc Hub 20 Brake Cam 5 Pad B 13 Special Screw 21 Special Washer 6 Brake Disc 14 Special Woodruff Key 22 Insert Nut 7 Brake Caliper Assembly 15...

Page 157: ...towards the 3 84 SLIDE RAIL SUSPENS ION bearing and the chain as a unit Install the lower sprocket bolt and washer torque 35 ft Ib 4 84 kg m Install the upper sprocket bolt and washer torque 40 to 50...

Page 158: ...132 Inspection Move slide ra il suspension back and forth on a level surface to check for binding See Fig ure 3 132 If the suspension bi nds locate the problem and refer to the appropriate repa ir pro...

Page 159: ...vet 34 Stopper Bumper 35 Back up Washer 36 Special Bolt 37 Spring Lock Washer Figure 3 133 3 86 FRONT IDLER SHAFT AND WHEELS 38 Special Cupped Washer 39 Spring 40 Spri ng Spacer 41 Front Suspension Br...

Page 160: ...4 72 I I 67 23 l_ I I Figure 3 133 FRONT IDLER SHAFT AND WHEELS 3 87...

Page 161: ...damage Replace as required 2 Check the limiter cross shaft and bell crank for distortion Removal 1 To remove the limiter remove the locknut se curing limiter to the bracket on the swing arm assembly...

Page 162: ...th a block of wood and hammer as illustrated in Figure 3 136 to remove it from the suspension rail Installation Install new rail wear strip by sliding it into posi tion on the suspension rail Secure w...

Page 163: ...cracked or worn rubber 3 Examine shock absorber spring for cracks wear or damage 4 Inspect bellcrank attaching points at each end of shock for damage Replace if necessary Removal 1 Remove the bolt fr...

Page 164: ...141 Swing Arm Inspection See Figure 3 142 1 Examine swing arms for distortion cracks or broken welds Replace if necessary 2 Remove spring and shock absorber 3 Remove and examine the pivot shafts for...

Page 165: ...s 2 Remove all rivets and bolts which secure sus pension rails to the suspension and slide out the rails from the suspension Installation 1 Reassemble suspension rails in the opposite order of removal...

Page 166: ...the bearing binds has excessive end play or is rough it must be replaced 2 Check the driveshaft for distortion Check the splined end for chipped nicked or broken splines 3 Check idler wheels for exce...

Page 167: ...es haft through the chaincase Be careful not to damage seal 3 Place the lock collar and bearing on the drive shaft from outside of chassis bearing flange 4 Install upper sprocket spacer upper and lowe...

Page 168: ...aft through brake disc assembly into chaincase 3 Sl ide lock collar and bearing onto jackshaft and into bearing housing Do not lock collar at this time Install bearing flange 4 Install upper sprocket...

Page 169: ...pole from turning over center during a full lock turn See Figure 3 150 6 ll 28 20 16 I 1 21 27 K J G I I 26 23 25 22 Lbr h I 32 I 23 25 24 21 27 22 3 96 STEERING AND SKIS 1 Figure 3 151 1 Panel Bracke...

Page 170: ...le and securing with bolt and washer Torque bolt to 30 ft Ib 4 2 kg mI 5 Install secondary tie rod to steering arms 6 Install handlebars reversing order of removal 7 Align skis and center steering pol...

Page 171: ...Saddle 7 Bolt 8 Monoleaf Spring 9 Spri ng Sleeve 10 Back Up Plate 11 Ski Bumper 3 98 STEERING AND SKIS b l 0 1 12 Bumper Retainer 13 Insert Nut 14 Insert Nut 15 Bolt 16 Ski 17 Skeg 18 Bolt 19 Rub Str...

Page 172: ...ig ure 3 153 2 Lift the seat from the snowmobile Installation 1 Position the seat on the snowmobile 2 Secure seat with the four seat mounting bolts Do not overtighten mounting bolts as blind nuts used...

Page 173: ...remaining oil and residue from tank with a mild solvent 2 Exami ne ta nk for damage cracks or leaks Repair or replace as necessary Allow solvent to dry from tank if the ta nk is to be reused 3 Be sur...

Page 174: ...bleed air from the line Reconnect the line and secure with clamp See Figure 3 156 Bleed the oil pump by removing the bleed bolt from the oil pump Hold control lever in the full open position until a...

Page 175: ...I 1 I J 1...

Page 176: ...Oil Recommendations 4 3 Break I n Procedure 4 3 Conversion Chart 4 4 Dril l Sizes 4 5 English to Metric Conversions 4 6 Unit Conversion Table 4 7 List of Abbreviations 4 7 Special Service Tools 4 8 W...

Page 177: ...f...

Page 178: ...e from pilot lights and sparks This snowmobile engine is automatically lubricated by a variable pump which may change the mixture from about 110 to 1 to about 25 to 1 depending on engine speed and thr...

Page 179: ...000 118110 3 0000 11 64 687500 17 4625 1 3 8 1 375000 34 9251 2 3 16 2 187500 55 5626 1 8 125000 3 1750 700000 17 7800 1 377963 35 0000 2 200000 55 8795 9 64 140625 3 5719 45 64 703125 17 8594 1 40000...

Page 180: ...834670 72 0000 3 3 16 3 187500 80 9627 3 543339 90 0000 3 897669 99 0000 2 27 32 2 843750 72 2314 3 189005 81 0000 3 550000 90 1691 3 900000 00 0591 2 850000 72 3893 3 200000 81 2793 3 9 16 3 562500...

Page 181: ...000 lb PRESSURE 1 Kilogram per Sq Cm 14 2233 Lbs per Sq In 1 Lb per Sq In 0 070307 Kilgms per Sq Cm 1 Kilogram per Sq Meter 0 20482 Lbs per Sq Ft 1 Lb per Sq Ft 4 8824 Kilgms per Sq Meter 1 Kilgm per...

Page 182: ...am kilograms in Ibs x 0115 kg m kg cm2 kilograms per square centimeter kg x 2 2046 lb kg m kilogram meters kg x 35 274 oz km kilometer kg m x 7 233 ft Ibs kph kilometers per hour kg m x 86 796 in Ibs...

Page 183: ...ton Ring Compressor Set SEALER LIQUID G ASKET Part No 92 104 002 Liquid Gasket Sealer LJI 1 rEI I I 101 0 1 Pa rt No 57001 3504 Shock Spring Compressor 4 8 SPECIAL SERVICE TOOLS Part No T56019 201 CD...

Page 184: ...CK YELLOW REO TACHOMETER w BROWN BROWN r REO r O STOP TAl L LIGHT 8 YELLOW YElLOWT o BROWN YELLOW YELLOW i13 BROWNIYELLOW BLACK I rr ENGINE CONNECTOR I r I VLlGHTINGCOIL c V WHITE l III SPEEDOMETER I...

Page 185: ...s 3 85 Front Springs 3 90 Fuel and Oil Recommendations 4 3 Fuel Pump 3 40 Fuel System Maintenance 2 30 Fuel Tank 3 99 Gear Ratio Chart 1 12 4 10 INDEX Page General Specif ications 1 2 Headlamp 3 66 Ig...

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Summary of Contents for Intruder 1978

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Suzuki Intruder 1978, Service Manual

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Summary of Contents for Intruder 1978

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