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PostPosted: Wed Oct 28, 2015 2:04 pm 
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I know some of us have identified several errors in the factory service manual. At least some of these errors have been replicated in the Clymer manual. I'd like to use this thread to document those errors all in one place.

The three main errors I can immediately think of are for the head bolt installation, which side the motor comes out of the frame, and the torque value for the lower shock bolt. Are there more?

We can't do anything about the Suzuki factory manual but last week I spoke to one of the service manual writers for Clymer/Haynes. He gave me his contact info to forward known errors so they can be corrected in the next edition.

What I want here are examples of errors in the factory manual which I will compare to the Clymer manual to see if they are repeated. Once I'm sure we know the things that should be fixed I'll send it off to Clymer.

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PostPosted: Wed Oct 28, 2015 2:04 pm 
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Here's a good post on the head bolt error

dobbo wrote:
Thorped wrote:
Hi I'm in a hurry getting my bike ready for spring... Today I were supposed to finish the engine but i can't get the cylinder head bolts installed the way the service manual says...

Image

This is the way it's suppose to be:
Image

But I can't get it in another way than this:
Image

B reaches the bottom before it's fully down. And the inside-C looks a bit "deep", meaning that the bolt head isn't far from the cylinder head while it's fully unscrewed.

I'm really confused, can I install the screws my way? :dunno:


THE CORRECT MEASUREMENTS

BOLT A: 200MM
BOLT B: 180MM
BOLT C: (BOTTOM LEFT OF PIC): 190MM
BOLT C: (BOTTOM RIGHT OF PIC): 180MM

I Measured each bolt as they came out, then followed the manual to refit them, only too find out the manual was wrong.
Luckily, I had written down the measurements on disassembly :biggrin:

cheers
Dobbo :2_thumbsup:

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PostPosted: Wed Oct 28, 2015 2:06 pm 
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Thread about which way to remove the motor from the frame:

http://drriders.com/post148791.html#p148791

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PostPosted: Wed Oct 28, 2015 5:18 pm 
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Great idea! I'll do some checking through the archives because I'm sure I've seen others mentioned, such as other questionable torque values. The suzuki service manual lists the torque values for the chassis bolts and nuts on page 2-15, so having a look at that might turn up something :search:

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PostPosted: Wed Oct 28, 2015 10:30 pm 
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Good idea Jeff. :2_thumbsup: I'm glad you got Clymer to listen. :friends:

The manual shows the washers at the red X, but they belong where the arrows show them, inside the dog bones.

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PostPosted: Wed Oct 28, 2015 10:46 pm 
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Excellent. Thanks!
:clapping:

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PostPosted: Wed Oct 28, 2015 10:49 pm 
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It would be awesome if somebody could modify the .pdf service manual with all of the corrections.

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PostPosted: Thu Oct 29, 2015 8:20 am 
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^^ Terrific idea. :good:

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PostPosted: Thu Oct 29, 2015 8:25 am 
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Excellent idea Jeff! :clapping: I'm going to move this to the Tech/Maintenance section and make it a sticky. :2_thumbsup:

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PostPosted: Thu Oct 29, 2015 9:31 am 
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Picard wrote:
It would be awesome if somebody could modify the .pdf service manual with all of the corrections.


:whistling: Someone MAY be working on that at this very moment..... :whistling:

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