Clymer M261-2 Suzuki 1500 Intruder Boulevard C90 Motorcycle Repair Manual (1998-2009)

1. Introduction

This Clymer repair manual, M261-2, provides detailed service and repair information for Suzuki 1500 Intruder and Boulevard C90 motorcycles manufactured between 1998 and 2009. It is designed for both the professional mechanic and the do-it-yourself enthusiast, offering step-by-step procedures, illustrations, and specifications to assist in maintenance, troubleshooting, and complete overhaul of your motorcycle.

Before beginning any work, it is crucial to read through the relevant sections completely to understand the procedures and safety precautions involved. Always use appropriate tools and safety equipment.

Image 1.1: Front cover of the Clymer M261-2 Repair Manual. This image displays the manual's title, applicable motorcycle models, and publication years, indicating its comprehensive nature for Suzuki 1500 Intruder and Boulevard C90 motorcycles from 1998 to 2009.

2. General Information and Safety

This section covers essential information applicable to all repair and maintenance tasks. It includes safety warnings, general workshop practices, and identification of motorcycle components.

2.1 Safety Precautions

• WARNING: Always wear appropriate safety gear, including eye protection and gloves, when performing maintenance or repairs.
• Ensure the motorcycle is stable on a suitable stand before beginning any work.
• Disconnect the battery ground cable before working on the electrical system.
• Allow the engine and exhaust system to cool completely before handling to prevent burns.

2.2 Tools and Equipment

A basic set of metric wrenches, sockets, screwdrivers, and pliers will be required. Specialized tools may be necessary for certain procedures and will be noted in the relevant sections.

3. Engine and Transmission

This section details procedures for the removal, inspection, repair, and reinstallation of the engine and transmission components. It covers cylinder head, piston, crankshaft, clutch, and gearbox service.

3.1 Oil Change Procedure

1. Warm the engine to operating temperature, then shut it off.
2. Place a drain pan beneath the engine oil drain plug.
3. Remove the drain plug and allow the oil to drain completely.
4. Replace the drain plug with a new washer and tighten to specified torque.
5. Remove and replace the oil filter.
6. Refill with the recommended type and quantity of engine oil.
7. Start the engine and check for leaks.

4. Chassis and Suspension

This section provides instructions for the maintenance and repair of the motorcycle's frame, steering, front forks, rear suspension, wheels, tires, and braking system.

4.1 Brake Pad Replacement

Regular inspection of brake pads is essential for safety. Replace pads when wear indicators are visible or pad material thickness is below the minimum specification.

• Remove the caliper mounting bolts.
• Slide out the old brake pads.
• Clean the caliper and push the pistons back into their bores.
• Install new brake pads and reassemble the caliper.
• Pump the brake lever until firm pressure is restored.

5. Electrical System

This section covers the battery, charging system, ignition system, lighting, switches, and wiring. Detailed wiring diagrams are included to aid in troubleshooting.

5.1 Battery Maintenance

Regular battery checks ensure reliable starting. Inspect terminals for corrosion, check electrolyte levels (if applicable), and ensure proper charging voltage.

6. Troubleshooting

This section provides diagnostic charts and procedures to help identify and resolve common issues. It covers problems related to engine starting, poor performance, electrical faults, and braking issues.

6.1 Engine Will Not Start

• Check Battery: Ensure battery is fully charged and terminals are clean.
• Check Fuel: Verify adequate fuel level and fuel flow to the carburetor/injectors.
• Check Spark: Confirm spark plugs are firing correctly.
• Check Compression: Perform a compression test if other checks are inconclusive.

7. Specifications

This section contains detailed technical specifications, including torque values, fluid capacities, wear limits, and adjustment settings for various components of the Suzuki 1500 Intruder and Boulevard C90 models.

Note: All torque specifications and fluid capacities are provided in detail within the manual's dedicated specifications chapter. Always refer to the manual for precise values.

8. Support and Warranty

This manual is published by Clymer, a division of Haynes Manuals. For questions regarding the content or corrections, please refer to the contact information provided within the physical manual or visit the official Clymer/Haynes website.

Warranty: This repair manual is intended as a guide. While every effort has been made to ensure accuracy, the publisher assumes no liability for errors or omissions, or for damages resulting from the use of the information contained herein. Always exercise caution and consult a qualified professional if unsure about any procedure.

For additional support or to purchase other Clymer manuals, please visit: Clymer Manuals Official Website