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Message started by Kropatchek on 06/26/05 at 01:53:17

Title: Suzuki/Clymer Manual Errors
Post by Kropatchek on 06/26/05 at 01:53:17

Like to start this here topic to list all the mistakes and/or errors that are written in the Suzuki Workshop Manual or Clymer Workshop Manual.

Here's the first one:

Rotate the engine in the direction it normaly turns.

As Greg already stated: in the same direction as the wheels turn.
OR
Anti-Clockwise (CCW) as seen from the Left Hand side of the bike.

(Clymer= Rotate Clockwise as seen from the LH side)


Greetz
Kropatchek ;D

Edited by Susan to change title from "WSM Against the Real World" to "Suzuki/Clymer Manual Errors

Title: Re: WSM Against the Real World
Post by Kropatchek on 06/28/05 at 07:34:57

Oil Quantity:

Overhauled engine    2400 cc  -  2.5 US Qt  -  2.1 Imp Qt

Oil AND filter change  2100 cc  -  2.2 US Qt  -  1.8 Imp Qt

Oil change                 1800 cc  -  1.9 US Qt  -  1.6 Imp Qt


Corrected from both Clymer and Suzuki.

Greetz
Kropatchek ;D

Some body will advice the missing figures?

Edit: corrected conversion, note 1000 cc = 1 liter

Title: Re: Suzuki/Clymer Manual Errors
Post by Kropatchek on 06/16/06 at 01:20:23

And another mistake:

Pointed out to a Dutch Savage rider.

The oilseals of the sliding members of the front suspension.

Fit them face up instead of face down.
That way the oil is kept in the struts.

(will refer to the pages when I get home)

Greetz
Kropatchek ???



Title: Re: Suzuki/Clymer Manual Errors
Post by TheFid on 11/23/06 at 06:19:16

Page 229 (electrical system) under paragraph headed LIGHTING SYSTEM referes to table 3. There is no table 3 in electrical chapter. I "e"mailed Clymer with this information and they replied by "e"mailing the table to me. Wether they update the manual is to be seen.

Title: Re: Suzuki/Clymer Manual Errors
Post by TheFid on 11/23/06 at 06:49:49



Sorry for the delay, as customer service 'lost' your e-mail and then I was away from the office.

Another sorry for the omission of Table 3.

Wattage for bulbs as follows:
Headlight    60/55
Tail/brake    8/23 or 5/21
Turnsignal    23 or 21
Speedo     3 or 3.4
Turn ind    3 or 3.4
High beam    1.7
Neutral        3 or 3.4
Licence light    8
Front position    8 or 5

Regards,
James Grooms
Managing Editor
Clymer Publications


Title: Re: Suzuki/Clymer Manual Errors
Post by vroom1776 on 01/12/07 at 16:37:12

In the factory service manual, the rear axle is shown being placed in the bike 180 degrees the wrong way (unless every savage I've ever seen has the rear axle in backwards).  The large nut should be on the left hand side of the bike, not the right.  The axle should slide in from the right hand side of the bike.

there are quite a few small errors like this throughout the clymer manual as well..

Title: Re: Suzuki/Clymer Manual Errors
Post by Greg_650 on 01/13/07 at 14:16:02


vroom1776 wrote:
In the factory service manual, the rear axle is shown being placed in the bike 180 degrees the wrong way (unless every savage I've ever seen has the rear axle in backwards).  The large nut should be on the left hand side of the bike, not the right.  The axle should slide in from the right hand side of the bike.


Aha....I've got that one for ya.

The axles get turned around because some mufflers tend to get in the way on the right side.  

Not sure if it changes anything as far as all the juggling of the belt,  pulley, spacers, wheel, and brake assembly.  Just about as much fun either way :P

Aside from that there is no difference in the axle..


Title: Re: Suzuki/Clymer Manual Errors
Post by bacon13 on 05/18/08 at 13:50:15

Clymer manual states under "plug removal" in tune up section to use a 17mm socket. It should be an 18mm instead.

Caused me two trips to parts store for the correct one. >:(

Title: Re: Suzuki/Clymer Manual Errors
Post by Savage_Rob on 05/20/08 at 06:04:21


787B7975742B291A0 wrote:
Clymer manual states under "plug removal" in tune up section to use a 17mm socket. It should be an 18mm instead.

Caused me two trips to parts store for the correct one. >:(

It's noted elsewhere on the site.  That size varies with different bikes.

Title: Re: Suzuki/Clymer Manual Errors
Post by Digger on 06/25/08 at 20:53:51


2E2A373735696F6F6E580 wrote:
In the factory service manual, the rear axle is shown being placed in the bike 180 degrees the wrong way (unless every savage I've ever seen has the rear axle in backwards).  The large nut should be on the left hand side of the bike, not the right.  The axle should slide in from the right hand side of the bike.

there are quite a few small errors like this throughout the clymer manual as well..


On mine (see signature), the nut is on the starboard side of the bike.  Pretty sure it came that way from the factory.

Title: Re: Suzuki/Clymer Manual Errors
Post by verslagen1 on 01/10/09 at 09:22:53

These are from the Suzuki Service Manual
http://www.savageriders.com/verslagen/images/ClutchExploded.jpg

http://www.savageriders.com/verslagen/images/ClutchPlateDims.jpg

Direct from an '86 SSM for a LS650.

And checked it against an '86-'88 Clymer, and they are correct.

I checked by 2004 Clymer and it is correct too.

Here's a clearer pic from Mekh...
http://suzukisavage.com/yabb2.2/Attachments/Clutch_Kobling_001.PNG

Title: Re: Suzuki/Clymer Manual Errors
Post by BouleTard on 06/14/09 at 09:32:20

The maintenance section says you have to remove and disassemble the forks to change the oil because there's no drain plug.  Then the fork diagram shows a drain plug.. I am very happy about this error.  ;)

Edit: no I'm not. The "drain screw" on the diagram is actually an axle pinch bolt.  Fork disassembly is required as described in the maintenance section.  :P

Title: Re: Suzuki/Clymer Manual Errors
Post by BuckRYCA on 06/19/12 at 20:46:42

Rotor Bolt:
Clymers says it is RH thread.

Previously this Forum listed it as one of three LH threads on the Savage.
(This has been removed.)

Clymers is correct. It's a RH thread, counterclockwise (CCW) to loosen and clockwise (CW) to tighten.

There are only two LH threads on the bike: Primary drive gear retaining nut and threaded nut on one end of the transmission shift rod.

Title: Re: Suzuki/Clymer Manual Errors
Post by TheFid on 07/20/12 at 22:49:32

Page 201 under fuel tank,Removal/instalation. para5 says,"turn the fuel shutoff valve to off." There is no off position.

Title: Re: Suzuki/Clymer Manual Errors
Post by BuckRYCA on 10/01/12 at 16:37:29

Clymers does not show the starter gear torque limiter on Starter Idle Gear #1. It shows the starter gear arrangement before it was redesigned to include a torque limiter (page 119).  

The torque limiter is shown as a single assembled unit on RonAyers.com parts fiche. There are no separate parts sold for it.

If you are removing the torque limiter/idle gear as part of an crankcase disassembly, do not remove the outboard circlip!  The torque limiter/gear may be removed by simply sliding it out.

The torque limiter has been assembled under tension. It will be difficult to impossible to re-assemble.

Title: Re: Suzuki/Clymer Manual Errors
Post by Digger on 08/22/13 at 19:05:49

Minor Clymer error, but an error nonetheless:

Chapter 11 (Brakes), Front Caliper section, Caliper Rebuilding Procedure:

Step #27 currently reads: Install the rubber boots (Figure 50) into the
receptacles in the caliper bracket


It SHOULD read: Install the rubber boots (Figure 50) into the
receptacles in the caliper body

Title: Re: Suzuki/Clymer Manual Errors
Post by wambr on 08/23/13 at 11:36:21

I think, it is appropriate to add that I found...
guide maintenance and repair of Kawasaki recommends that you check the belt tension..

Title: Re: Suzuki/Clymer Manual Errors
Post by wambr on 08/23/13 at 11:59:02

I mean that many people ask about how to properly adjust the belt tension....(this is another options)

Title: Re: Suzuki/Clymer Manual Errors
Post by Kris01 on 10/15/14 at 16:20:44

Page 343 - Staring system should read starting system   ;D

Title: Re: Suzuki/Clymer Manual Errors
Post by Jeff71 on 11/12/14 at 22:47:40

Look at the wiring on p.351 and 353. The B/W wire coming from the rear brake light switch connects to the wrong wire on the tail/brake light!
Jeff

Title: Re: Suzuki/Clymer Manual Errors
Post by Drestakil on 10/09/15 at 12:26:50

Pretty obvious but on page 59 #10 "rotate engine additional 180". It should read rotate 360 as it does on page 49 #9.

Title: Re: Suzuki/Clymer Manual Errors
Post by RevJay on 04/04/17 at 07:30:30


754C514E5F4A5D565B553E0 wrote:
And another mistake:

Pointed out to a Dutch Savage rider.

The oilseals of the sliding members of the front suspension.

Fit them face up instead of face down.
That way the oil is kept in the struts.

(will refer to the pages when I get home)

Greetz
Kropatchek ???


Title: Re: Suzuki/Clymer Manual Errors
Post by RevJay on 04/04/17 at 07:35:29

Page 276
9b  Position the seal with the open groove facing upward (pic) and slide oil seal (c) down onto the fork tube.

I have never been instructed to do it this way  surely the seal goes open groove down ??
Jay

Title: Re: Suzuki/Clymer Manual Errors
Post by verslagen1 on 04/04/17 at 09:01:04

Our HowTo says...

302F22353A430 wrote:
install the new seal the same way /MAKE SURE THE LETTERS AND NUMBERS ARE FACING UP/. Install the retaining clip and the dust seal.


This would make sense as the groove side of the seal is normally installed on the pressure side.  This increases seal pressure during the time it's most likely to leak.

Title: Re: Suzuki/Clymer Manual Errors
Post by ET on 08/31/17 at 06:11:12

Front turn signals wiring errors...

On page 354 of the Clymer manual, the wire to the Left Front Turn Signal (bottom connection) is shown going to the wrong wire. It shows it going to GND instead of the turn signal switch BLACK wire.

The BLACK wire is instead shown going to the Right Turn Signal center connector which SHOULD be shown going to GND.

Title: Re: Suzuki/Clymer Manual Errors
Post by Christof13T on 09/29/17 at 23:46:07

Page 15
General Information...

Hammers (fig 37) is Ignition Gauge in the picture.

Ignition gauge (fig 38) is Hammers in the picture.

Wanted to make sure nobody got confused, that might get messy...

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