Suzuki Intruder 1978 - Headlamp; Key Switch

4. Loosen lock screw and slide throttle lever
assembly
from the handlebar. (See Figure 3-
89 .)
1. Eme
rg ency Stop Switch 6. Pin Washer
2. Thr ottle Case Plate
7. Pin Retainer
3. Lock Screw 8. Throttle Case
4. Lever Pin 9.
Plate Sc r ew
5. Throttle Lever
Figure
3-89
5. Remove the screw securing throttle case plate
to the case and remove the plate. The emer-
gency stop sw i tch can now be slid out of the
case and a re pl acement slid in.
6. To replace the lever, remove retainer, washer
and pin.
Installation
1. Install the components and the throttle lever
assemb ly in the reverse order of removal.
Torque the lock screw to 25 in. Ib (0.29 kg-mI.
2. Check the throttle lever adjustment as
descr
ib ed in Section 2.
Headlamp
Removal
1. To remove just the headlamp assembl y, dis-
connect the head lamp harness from the
head la mp.
2. Remove the four adjusting screws and springs.
The
headlamp assembly can now be removed
from
the hood.
Disassemble headlamp as ill ustrated in Figure 3-
90 .
3-66 KEY SWITCH
1. Headlamp Assembly
2. Headlamp Lens
3. Headlamp Bulb
4. Upper Adjusting Screw
5. Adjustment Spring
6. Retainer
7.
Headlamp Harness
Figure
3-90
Installation
1. Reassemble headlamp in reverse order of re-
moval. (See Figure 3- 90 .)
2. Adjust headlamp in accordance with Section 2.
Key Switch
Removal
1. Remove the air silencer.
2. Remove the ha ndlebars.
3. Remove the handlebar holder.
4. Remove the two upper steering mount bolts.
Lift the ke y switch panel and bracket up. Dis-
connect the
wiring harness from the key
switch.
5. Remove the face nut from the key switch. Re-
move the
switch from the panel. (See Figure 3-
91.)
Installation
1. Install the ke y switch in the reverse order of
remova l. Hand tighten the face nut. Torque the
upper steering
mount bolts to 18 ft Ib (2 .5 kg -
mI. Torque the handlebar holder bolt to 35 ft I
(4.84 kg -m I. Torque the four socket screw s
securing
the handleholder to 105 in. Ib (1.21
kg-mI·
,