GAUGES AND INSTRUMENTS 2.1
GENERAL
Use the troubleshooting tables on the following pages to
diagnose and locate problems with malfunctioning or inoperative
instruments and gauges. For wire connections at rear of
gauges, see Figure 2-1. Refer to the applicable wiring diagram
at the back of this book for further assistance.
DIAGNOSTICS
Fuel Level Gauge
When the Ignition/Light Key Switch is turned to IGNITION,
the fuel gauge is connected to + 12 vdc. Current flows
through the gauge and variable resistor in the fuel level
sender to ground. The sender unit float controls the amount
of resistance in the variable resistor.
Fuel Level Sender Test
1. See the following chart and “ground” the applicable test
point.
2. Turn the Ignition/Light Key Switch to IGNITION. If gauge
indicated FULL, gauge is functioning correctly. Proceed
to step 3. If gauge did not indicate FULL, proceed to step
4.
3. With the Multi-Meter, Part No. HD-35500A, set on the
RXI scale, measure the resistance of the sender unit.
Place one probe on the center terminal and the other
probe on a good ground.

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1. 2007 Suzuki S83
2. Suzuki S83 Review
3. 2005 Suzuki S83

Oil Pressure Gauge and Indicator Light
Problem:
Low oil pressure light remains on with engine
running above idle and/or oil pressure gauge does not work.
Ambient Air Temperature Gauge
Problem:
Gauge inoperative.
Cause Solution
No oil pressure due to lack of oil or
faulty oil pump.
Running engine when OIL pressure light remains on and gauge indicates
low pressure will result in engine damage.
1. Check oil level. Add oil if low.
2. Restart engine and verify that oil pressure light goes off and gauge indicates
pressure. If problem still exists, refer to OIL PUMP in the Service
Manual (Part Number 99483-02).
Contacts in pressure sending unit
not opening to shut off light.
Variable resistor in sender is
shorted to ground.
1. Locate the oil pressure sending unit on the front right side of the crankcase.
2. Verify that the electrical connector is properly connected to the sending unit.
3. If the oil pressure gauge indicates pressure but the low oil pressure light remains
on, proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Place one
ohmmeter probe on indicator lamp terminal (closest to latch), place the other
probe on the crankcase. Meter must read zero ohms.
b. Start the engine and run at a fast idle. The ohmmeter must read infinity.
c. Replace the sending unit if the above meter readings are
not
obtained.
4. If the low oil pressure light functions correctly, but the pressure gauge does not,
then proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Turn the Ignition/
Light Key Switch to IGNITION. The gauge must read zero.
b. Ground BN/GN wire terminal to crankcase. The gauge must read full scale 70
PSI.
c. Replace the sending unit if the above gauge readings are obtained. If the
gauge readings are
not
obtained, then replace the pressure gauge.
No power to gauge. See Voltmeter.
CAUTION
Cause Solution
Sensor not grounded or open
between sensor and gauge.
Test for continuity between pin 1 and ground and pin 3 and gauge. Repair if open.
Broken or disconnected power or
ground wire to gauge.
Check for 12 vdc between pins 1 and 3 at connector [115A]. Replace gauge if voltage
is present. Use voltage drop tests and continuity checks to isolate if voltage is not
present.
Malfunction in gauge or sensor.
Measure resistance between pins 1 and 3 at 65° to 85° F. Resistance should be 43-31
ohms. Replace sensor if out of range, replace gauge if within range.
Instruments
HOME
Voltmeter
Problem:
Meter inoperative.
Indicator Lights: FLHR/C
Problem:
Light(s) inoperative.
Cause Solution
Broken or disconnected leads to meter
or open meter winding.
1. With Ignition/Light Key Switch turned to IGNITION, verify that 12 vdc is
present at “±” terminal on voltmeter. With switch turned to OFF, check
ground terminal for continuity to ground.
2. Replace the voltmeter if 12 vdc is present and ground terminal is grounded.
3. If 12 vdc is not present, trace wiring until disconnected or broken wire is
found and repair as necessary. If ground terminal is not grounded, refer to
wiring diagram and repeat procedure given for 12 vdc lead.
Ground Present at Pin
2 of Connector [21A]?
Ground through switch
Ground through switch
Oil Pressure Indicator
Neutral Indicator
High Beam Indicator
R/L Turn Indicator 12V when active
Oil Pressure or Neutral Indicator High Beam or R/L Turn Signal Indicator
Check for 12V at
Pin 6 of Connector
[21A]. Is 12V
Present?
Replace Indicator
Lights Assembly.
Is 12V Present when
Circuit is Active?
NOTE
Use Pin 1 (Left Turn),
Pin 4 (Right Turn) and
Pin 2 (High Beam).
Locate and
Repair Open
in Circuit.
Replace Indicator
Lights Assembly.
NOTE
12V when active
Indicator Lights Connector [21]
Terminal Wire Color Indicator
1 Violet Left Turn
2 White High Beam
3 Green/Yellow Oil Pressure
4 Brown Right Turn
5 Tan Neutral
6 Orange Neutral/Oil Pressure
7 Black Right/Left Turn/High Beam
8 Not Used Not Used
Replace Oil
Pressure
Switch.
Repair Open in GN/Y
Wire (Oil psi) or TN
Wire (Neutral).
5161
Replace
Neutral Switch.
Is There Continuity
to Ground Through
Switch?
5191
5048
5157
5048
5048
Locate and
Repair Open
in Circuit.
5048
5191
YES NO
1
YES
Is There Continuity to
Ground at Pin 5 (Neutral)
and Pin 3 (Oil psi) of
Connector [21]?
Check Fuses
or Find Open.
YES NO NO
NO
2
NO
NO
YES
YES
Will Not Function Will Not Function
Instruments 2-5
HOME
SPEEDOMETER 2.2
GENERAL
NOTE
The performance (proper operation and sweeping action) of
the speedometer can be evaluated using the Speedometer
Tester (HD-41354). Before replacing the speedometer, see
Section 2.3 SPEEDOMETER PERFORMANCE CHECK.
The electronic speedometer consists of a speed sensor,
reset switch and speedometer unit.
The Hall-Effect speed sensor circuitry is triggered by the
teeth of the transmission mainshaft 4th gear. The sensor output
is a series of pulses that are interpreted by the speedometer
circuitry to control the position of the speedometer
needle and the odometer’s liquid crystal display (LCD). The
odometer mileage is permanently stored and is not lost when
electrical power is turned off or disconnected.
NOTE
Circuitry in the speedometer also conditions the sensor input
to provide an input to the turn signal canceler.
By momentarily pressing the reset switch, the user is able to
toggle between the odometer and trip odometer displays. To
zero the trip odometer, depress and hold the reset switch
while the odometer display is visible. The trip odometer mileage
will then appear for approximately 2-3 seconds, after
which time the recorded figure is zeroed.
The odometer can display seven numbers to indicate a maximum
of 999999.9 miles. The trip odometer can display five
numbers for a maximum of 9999.9 miles.
Reset Switch
See Figure 2-2. Besides toggling between the odometer and
trip odometer displays, the reset switch is also used to identify
the speedometer pulses per unit and to enter the diagnostic
mode. In the diagnostic mode, the user can display the
fault codes stored in memory. The fault codes assist the user
in troubleshooting speedometer problems.
Diagnostic Mode
To enter the diagnostic mode, hold the reset switch in and
turn the Ignition/Light Key Switch from OFF to IGNITION. The
normal power-up sequence occurs before the diagnostic
mode is entered. Any diagnostic codes set during this powerup
sequence also will be stored.
IMPORTANT NOTE
Holding the reset switch in for more than 5 seconds while in
the diagnostic mode will clear all set diagnostic codes from
memory.

SCHEDULED MAINTENANCE TABLE 1.4
The scheduled maintenance table beginning on this page
lists the maintenance requirements for Touring model motorcycles.
If you are familiar with the procedures, just reference
the table for the recommended maintenance interval as well
as the required specifications. On the other hand, if more
information is needed, simply turn to page 14 for the start of
more detailed service procedures. For your added convenience,
the adjacent chart lists the part numbers of the
required lubricants.
Lubricant Part Number
Engine Oil See Table 1-1.
Front Fork Oil
Hydraulic Fork Oil, Type “E”,
H-D Part No. 99884-80/16 oz.
Silicone Brake Fluid
D.O.T. 5 Hydraulic Brake Fluid,
H-D Part No. 99902-77/12 oz.
Transmission Lubricant
Semi-Synthetic Transmission Lubricant,
Part Nos. 98853-96/case qt.,
98852-96/case gal.
Chaincase Lubricant
Primary Chaincase Lubricant,
Part Nos. 99887-84/qt., 99886-84/gal.
Clutch and Throttle Cable
Lubricant
Super Oil, Part No. 94968-85TV
Steering Head Bearing
Lubricant
Special Purpose Grease,
Part No. 99857-97/cartridge
Electrical Contact
Lubricant
Electrical Contact Grease,
Part No. 99861-90

SPARK PLUG
NOTE
Be sure spark plugs are gapped to specification before
installation.
TORQUE VALUES
Part No. No. Size Gap
32317-86A 6R12 12 mm
0.038-0.043 in.
0.97-1.09 mm
Item ft/in-lbs Nm
Ignition module socket
head screws
50-60
in-lbs
5.7-6.8 Nm
MAP sensor TORX screw 25-35
in-lbs
2.8-4.0 Nm
Ignition coil bracket
socket screws
84-144
in-lbs
9.5-16.3 Nm
Spark plug 12-18 ft-lbs 16-24 Nm
Stator to crankcase TORX
screws
55-75
in-lbs
6.2-8.5 Nm
Battery cable bolt 60-96
in-lbs
6.8-10.9 Nm
Voltage regulator locknuts 70-100
in-lbs
7.9-11.3 Nm
Main 40 amp circuit
breaker Keps nuts
20-35
in-lbs
2.3-4.0 Nm
Battery hold-down clamp
TORX bolt 15-20 ft-lbs 20-27 Nm
Passing lamp bracket fork
side TORX bolts
15-20 ft-lbs 20-27 Nm
Passing lamp bracket fork
side stud acorn nuts
72-108
in-lbs
8.1-12.2 Nm
Tail lamp lense screws 20-24
in-lbs
2.3-2.7 Nm
Tail lamp circuit board/
plastic bracket
40-48
in-lbs
4.5-5.4 Nm
Rear fender tip lamp nuts 20-25
in-lbs
2.3-2.8 Nm
Front fender tip lamp nuts 20-25
in-lbs
2.3 - 2.8 Nm
Front fender trim strip tee
bolt nuts
10-15
in-lbs
1.1-1.7 Nm
Ignition switch to triple
clamp screws
36-60
in-lbs
4.1-6.8 Nm
Fairing cap TORX screws 25-30
in-lbs
2.8-3.4 Nm
Ignition switch button
head screws
18-23
in-lbs
2.0-2.6 Nm
Instrument bezel TORX
screws
25-35
in-lbs
2.8-4.0 Nm
Continued ..
Item ft/in-lbs Nm
Handlebar clamp to
master cylinder housing
screws
60-80
in-lbs
6.8-9.0 Nm
Lower and upper handlebar
switch housing TORX
screws
35-45
in-lbs
4-5 Nm
Handlebar clamp to
clutch lever bracket TORX
screws
60-80
in-lbs
6.8-9.0 Nm
Neutral switch 10-15 ft-lbs 14-20 Nm
Horn stud flange nut
(10mm)
80-100
in-lbs
9.0-11.3 Nm

Complete coverage for your vehicle

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Written from hands-on experience gained from the complete strip-down and rebuild of a Suzuki Boulevard S83, Haynes can help you understand, care for and repair your Suzuki Boulevard S83. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Suzuki Boulevard S83 can help maintain its resale value, save you money, and make it safer to ride.

Printed manual

2007 Suzuki S83

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What's covered

Table of contents

This Suzuki Boulevard Manual is 440 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Torque specifications / Special tips / Fasteners / Lubricants / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic's tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Poor idle speed performance / Poor medium and high speed performance / Engine starting system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Engine leakdown test / Clutch / Transmission / Final drive / Handling / Frame noise / Brakes / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-ride inspection / Service intervals / Tires and wheels / Battery / Battery electrical cable connectors / Periodic lubrication / Engine oil and filter change / Engine oil pressure test / Final drive oil change / Speedometer cable lubrication / Swing arm bearing assembly lubrication / Periodic maintenance / Throttle grip free play / Automatic compression release cable free play check and adjustment / Air filter / Steering head adjustment check / Tune-up / Compression test / Spark plugs / Ignition timing / Carburetor idle speed adjustment / Carburetor idle mixture / Carburetor cable synchronization / Specifications

CHAPTER FOUR / ENGINE UPPER END
Engine principles / Servicing engine in frame / Engine / Front cylinder head cover and camshaft / Rear cylinder head cover and camshaft / Camshaft / Rocker arm assemblies / Hydraulic tappets (valve lash adjusters) / Cylinder head and cylinder / Valves and valve components / Pistons and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END
Oil cooler / Primary drive gear and rear cylinder camshaft chain and sprocket / Secondary gear assembly / Crankcase / Engine break-in / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
External gearshift mechanism / Clutch / Clutch hydraulic system / Master cylinder / Slave cylinder / Bleeding the system / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission / Internal gearshift mechanism / Specifications

CHAPTER EIGHT / FUEL, EMISSION CONTROL AND EXHAUST SYSTEM
Carburetor operation / Carburetor service / Carburetor assembly / Carburetor service / Carburetor adjustments / Throttle cable replacement / Fuel tank / Fuel shutoff valves / Fuel pump / Crankcase breather system (U.S. only) / Evaporative emission control system (California models only) / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Basic information / Electrical connectors / Battery negative terminal / Charging system / Voltage regulator/rectifier / Alternator / Transistorized ignition system / Automatic compression release control and starter system / Electric starter / Starter clutch and gears / Starter relay / Lighting system / Switches / Electrical components / Fuses / Wiring diagrams / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tires / Tire changing / Tire repairs / Handlebar / Steering head and stem / Steering head bearing races / Front fork / Specifications

CHAPTER ELEVEN / REAR SUSPENSION AND FINAL DRIVE
Rear wheel / Rear hub / Final drive unit, drive shaft and universal joint / Swing arm / Shock absorbers / Specifications

CHAPTER TWELVE / BRAKE SYSTEM
Disc brakes / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Brake caliper disassembly/inspection/assembly (all models) / Rear master cylinder / Brake hose replacement / Brake disc / Bleeding the system / Rear brake pedal / Specifications

CHAPTER THIRTEEN / BODY AND FRAME
Seats / Frame side covers / Frame head side covers / Footpegs / Sidestand / Front fender / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
2005 2006 2007 Suzuki Boulevard S83
1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 Suzuki VS1400 Intruder

Clymer Manuals Suzuki Boulevard S83 Manual
Clymer Manuals Suzuki VS1400 Intruder Manual

VS1400 Intruder (1987-2004)
Boulevard S83 (2005-2007)

Online manual

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Suzuki S83 Review

Key features:

2005 Suzuki S83

• All colour step-by-step guides for over 200 jobs with 700+ photos
• Image zoom feature for close-up view of jobs
• Brand-new “how to” video tutorials covering key repair tasks
• Print complete sections to take with you into the workshop
• Troubleshooting section – quickly find the cause of a problem
• Colour wiring diagrams help track problems quickly and easily
• Easy search feature – find your job fast
• Dictionary of automotive terms
• Quick links to popular DIY tasks and other jobs linked to your task
• Conversion calculator – imperial and metric units