1-ii Table of Contents
PAIR Reed Valve Removal and Installation........1B-8
PAIR Control Solenoid Valve Removal and
Installation.........................................................1B-9
PAIR System Inspection .....................................1B-9
Crankcase Breather (PCV) Hose Inspection.....1B-10
Crankcase Breather (PCV) Hose Removal
and Installation ................................................1B-11
Evaporative Emission Control System
Removal and Installation (Only for E-33) ........1B-11
Evaporative Emission Control System
Inspection (For E-33 only)...............................1B-12
Specifications.....................................................1B-14
Special Tools and Equipment ...........................1B-14
Engine Electrical Devices....................... 1C-1
Precautions...........................................................1C-1
Precautions for Engine Electrical Device ............1C-1
Component Location ...........................................1C-1
Engine Electrical Components Location .............1C-1
Diagnostic Information and Procedures............1C-1
Engine Symptom Diagnosis ................................1C-1
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
CKP Sensor Inspection .......................................1C-1
CKP Sensor Removal and Installation ................1C-1
IAP Sensor Inspection.........................................1C-1
IAP Sensor Removal and Installation..................1C-2
TP Sensor Inspection..........................................1C-2
TP Sensor Removal and Installation...................1C-2
TP Sensor Adjustment ........................................1C-3
IAT Sensor Removal and Installation..................1C-3
ECT Sensor Removal and Installation ................1C-4
ECT Sensor Inspection .......................................1C-5
TO Sensor Removal and Installation ..................1C-5
TO Sensor Inspection .........................................1C-6
STP Sensor Inspection .......................................1C-6
STP Sensor Adjustment......................................1C-6
STP Sensor Removal and Installation ................1C-7
STV Actuator Inspection .....................................1C-8
STV Actuator Removal and Installation ..............1C-8
ISC Valve Inspection...........................................1C-8
ISC Valve Removal and Installation....................1C-8
ISC Valve Preset and Opening Initialization .......1C-8
HO2 Sensor Inspection .......................................1C-9
HO2 Sensor Removal and Installation ................1C-9
GP Switch Inspection ..........................................1C-9
GP Switch Removal and Installation ...................1C-9
Specifications.....................................................1C-10
Special Tools and Equipment ...........................1C-11
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram ........................1D-1
Throttle Cable Routing Diagram..........................1D-2
Diagnostic Information and Procedures ............1D-3
Repair Instructions ..............................................1D-4
Engine Components Removable with the
Engine in Place .................................................1D-4
Air Cleaner Element Removal and Installation ....1D-6
Air Cleaner Element Inspection and Cleaning ....1D-7
Air Cleaner Chamber Removal and
Installation .........................................................1D-7
Throttle Body Components .................................1D-9
Throttle Body Construction................................1D-10
ISC Valve Removal and Installation..................1D-12
Throttle Body Removal and Installation ............1D-12
Throttle Body Disassembly and Assembly........1D-14
Throttle Body Inspection and Cleaning .............1D-17
Throttle Valve Synchronization .........................1D-18
ISC Valve Reset................................................1D-20
Engine Assembly Removal ...............................1D-20
Engine Assembly Installation ............................1D-24
Engine Top Side Disassembly ..........................1D-27
Engine Top Side Assembly ...............................1D-32
Valve Clearance Inspection and Adjustment ....1D-41
Cylinder Head Cover Inspection .......................1D-41
Camshaft Inspection .........................................1D-41
Automatic-decomp. Inspection..........................1D-43
Cam Chain Tension Adjuster Inspection...........1D-43
Cylinder Head Cover Disassembly and
Assembly.........................................................1D-44
PAIR Reed Valve / PAIR Reed Valve Cover
Inspection........................................................1D-45
Cylinder Head Disassembly and Assembly ......1D-45
Cylinder Head Related Parts Inspection ...........1D-47
Valve Guide Replacement ................................1D-50
Valve Seat Repair .............................................1D-52
Cam Chain Guide Inspection ............................1D-53
Cylinder Inspection............................................1D-53
Piston Ring Removal and Installation ...............1D-53
Piston and Piston Ring Inspection ....................1D-55
Engine Bottom Side Disassembly .....................1D-56
Engine Bottom Side Assembly..........................1D-64
Cam Chain Tensioner Inspection......................1D-73
Conrod Removal and Installation ......................1D-74
Conrod / Crankshaft Inspection.........................1D-75
Conrod Crank Pin Bearing Inspection and
Selection .........................................................1D-76
Crankshaft Bearing Inspection and
Adjustment ......................................................1D-77
Crankshaft Bearing Replacement .....................1D-78
Crankshaft Thrust Clearance Inspection and
Adjustment ......................................................1D-80
Specifications .....................................................1D-82
Service Data......................................................1D-82
Tightening Torque Specifications......................1D-84
Special Tools and Equipment ...........................1D-85
Summary of Contents for Intruder VZ1500
Page 2: ......
Page 4: ......
Page 14: ...00 9 Precautions ...
Page 62: ...0C 12 Service Data ...
Page 190: ...1D 1 Engine Mechanical Engine Engine Mechanical Schematic and Routing Diagram ...
Page 484: ...4C 10 Rear Brakes ...
Page 522: ...5C 17 Clutch ...
Page 536: ...6B 11 Steering Handlebar ...
Page 580: ...Prepared by September 2008 Part No 99500 39370 03E Printed in U S A 580 ...