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Suzuki Intruder VL1500B Owner's Manual

Summary of Intruder VL1500B

  • Page 1

    99011-06j52-01a vl1500b/t/bt printed in japan part no. 99011-06j52-01a december, 2014 en vl1500b/t/bt owner’s manual l5 tk c © copyright suzuki motor corporation 2014 cyan magenta yellow black 8 mm vl1500b/t/bt (99011-06j52-01a) 4 /1 top 1st cover 4th cover.

  • Page 2

    This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle....

  • Page 3: Break-In (Running-In)

    Important break-in (running-in) information for your motorcycle the first 1600 km (1000 miles) are the most important in the life of your motorcycle. Proper break-in operation during this time will help ensure maximum life and perfor- mance from your new motorcycle. Suzuki parts are manufactured of ...

  • Page 4:  Warning

    warning/caution/notice/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol  and the words warning, caution, notice and note have special meanings. Pay particular atten- tion to messages highlighted by these signal words: note: indicates...

  • Page 5

    Foreword motorcycling is one of the most exhilarating sports and to ensure your riding enjoyment, you should become thoroughly familiar with the information presented in this owner’s manual before riding the motorcycle. The proper care and maintenance that your motorcycle requires is outlined in thi...

  • Page 7: Table of Contents

    Table of contents 1 2 3 4 5 6 7 8 consumer information controls fuel, oil and coolant recommendations break-in (running-in) and inspection before riding riding tips inspection and maintenance troubleshooting storage procedure and motorcycle cleaning specifications index.

  • Page 9: Consumer Information

    1-1 1 consumer information accessory use and motorcycle loading ................................................................................ 1-2 safe riding recommendation for motorcycle riders ....................................................... 1-6 labels ......................................

  • Page 10: Accessory Use and Motorcycle

    1-2 consumer information accessory use and motorcycle loading accessory use the addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for suzuki to test each accessory on the market or combinations of all the available accessories; however, your dealer can as...

  • Page 11

    1-3 accessory installation guidelines • install aerodynamic-affecting accesso- ries, such as a fairing, windshield, back- rests, saddlebags, and travel trunks, as low as possible, as close to the motorcy- cle and as near to the center of gravity as is feasible. Check that the mounting brackets and o...

  • Page 12:  Warning

    1-4 loading limit • never exceed the g.V.W. (gross vehicle weight) of this motorcycle. The g.V.W. Is the combined weight of the machine, accessories, payload, rider and passen- ger. When selecting your accessories, keep in mind the weight of the rider as well as the weight of the accessories. The ad...

  • Page 13:  Warning

    1-5 loading guidelines this motorcycle is primarily intended to carry small items when you are not riding with a passenger. Follow the loading guide- lines below: • balance the load between the left and right side of the motorcycle and fasten it securely. • keep cargo weight low and close to the cen...

  • Page 14: Motorcycle Riders

    1-6 safe riding recommendation for motorcycle riders motorcycle riding is great fun and an excit- ing sport. Motorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider and passen- ger. These precautions are: wear a helmet motorcycle safety equipment starts...

  • Page 15

    1-7 know your limits ride within the boundaries of your own skill at all times. Knowing these limits and stay- ing within them will help you to avoid acci- dents. Be extra safety conscious on bad weather days riding on bad weather days, especially wet ones requires extra caution. Braking dis- tances...

  • Page 16: Labels

    1-8 labels read and follow all the labels on the motor- cycle. Make sure you understand all of the labels. Do not remove any labels from the motorcycle. Serial number location the frame and/or engine serial numbers are used to register the motorcycle. They are also used to assist your authorized suz...

  • Page 17

    1-9 the frame number 1 is stamped on the steering head. The engine serial number 2 is stamped on the crankcase assembly. Please write down the numbers in the box provided below for your future reference. Frame number: engine number:.

  • Page 18: Noise Control System

    1-10 noise control system (australia only) tampering with noise control system prohibited owners are warned that the law may pro- hibit: (a) the removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorpo- r...

  • Page 19: Controls

    2-1 2 controls location of parts ............................................................................................................................... 2-2 key ......................................................................................................................................

  • Page 20: Location of Parts

    2-2 controls location of parts 1 clutch lever 2 left handlebar switches 3 instrument panel 4 front brake fluid reservoir 5 right handlebar switches 6 throttle grip 7 front brake lever 8 fuel tank cap vl1500b vl1500t/bt.

  • Page 21

    2-3 9 air cleaner 0 spark plug a ignition switch b tools c battery and main fuse d helmet holder e sidecase (vl1500t/bt) f gearshift lever g engine oil filter h footrests i engine oil filler cap j side stand k engine oil drain plug l speed sensor m engine coolant reservoir n passenger footrests vl15...

  • Page 22

    2-4 o fuses p rear brake fluid reservoir q steering lock r rear brake light switch s rear brake pedal vl1500b vl1500t/bt.

  • Page 23: Key

    2-5 key this motorcycle comes equipped with a main ignition key and a spare one. Keep the spare key in a safe place. Ignition switch the ignition switch has 3 positions: “off” position all electrical circuits are cut off. The engine will not start. The key can be removed..

  • Page 24:  Warning

    2-6 “on” position the ignition circuit is completed and the engine can now be started. The headlight and taillight will automatically be turned on when the key is in this position. The key can- not be removed from the ignition switch in this position. Note: start the engine promptly after turn- ing ...

  • Page 25: Steering Lock

    2-7 steering lock turn the handlebars all the way to the left. Insert the ignition key into the steering lock and turn it counterclockwise to lock the steering.  warning moving the motorcycle while the steer- ing is locked can be hazardous. You could lose your balance and fall, or you could drop th...

  • Page 26: Instrument Panel

    2-8 instrument panel speedometer 1 the speedometer indicates the road speed in kilometers per hour and miles per hour. If the speedometer needle does not point to zero, follow the procedure below to reset the speedometer. 1. Press and hold the button 9 and turn on the ignition switch. 2. Hold the bu...

  • Page 27: Notice

    2-9 turn signal indicator light “ ” 2 when the turn signals are being operated either to the right or to the left, the indicator light will blink intermittently. Note: if a turn signal light is not operating properly due to bulb filament or circuit fail- ure, the indicator light blinks more quickl...

  • Page 28: Notice

    2-10 coolant temperature indicator light “ ” 5 this indicator light comes on when the cool- ant temperature indicates more than 120°c (248°f). When the coolant temperature indi- cator light comes on, stop the engine and check the coolant level after engine cools. Fi e f a b gear notice riding the m...

  • Page 29: Notice

    2-11 fuel injection system indicator light “fi” 6 if the fuel injection system fails, the red indi- cator light 6 comes on and the display indi- cates “fi” at the clock display in the following two modes; a. The display 7 in the odometer display area indicates “fi” intermittently, and the red indica...

  • Page 30

    2-12 note: • if the display indicates “fi” intermittently and the red indicator light comes on and remains lit, keep the engine running and bring your motorcycle to an authorized suzuki dealer. If the engine stalls, try restarting the engine after turning the ignition switch off and on. • if the dis...

  • Page 31

    2-13 when the display indicates “chec”, check the following items; • make sure that the engine stop switch is in the “ ” position. • make sure that the transmission is in neutral or the side stand is fully up. If the display still indicates “chec” after checking the above items, inspect the igni- t...

  • Page 32

    2-14 to change the display, push the button 8. The display changes in the order below. Fi e f a b gear gear a gear b gear gear odometer trip meter a trip meter b instrument panel light brightness.

  • Page 33:  Warning

    2-15 clock the clock has a 12-hour display. Follow the procedure below to adjust the clock. 1. Push the buttons, 8 and 9, simulta- neously for 2 seconds until the hour dis- play blinks. 2. Adjust the hour display by pushing the button 9. Note: when the button 9 is held in the dis- play advances cont...

  • Page 34

    2-16 odometer the odometer registers the total distance that the motorcycle has been ridden. The odometer ranges from 0 to 999999. Note: the odometer display locks at 999999 when the total distance exceeds 999999. Fi e f a b gear.

  • Page 35

    2-17 trip meters the two trip meters are resettable odome- ters. They can register two kinds of dis- tances at the same time. For instance, trip meter a can register the trip distance and trip meter b can register the distance between fuel stops. To reset a trip meter to zero, push the button 9 for ...

  • Page 36

    2-18 fuel meter “ ” 0 the fuel meter indicates the amount of fuel remaining in the fuel tank. The fuel meter displays all 5 segments when the fuel tank is full. The segment comes on when the fuel level drops below 3.7 l (3.9/3.3 us/imp qt). The segment blink when the fuel drops below 2.0 l (2.1/1.8...

  • Page 37: Left Handlebar

    2-19 high beam indicator light “ ” a this blue indicator light will come on when the headlight high beam is turned on. Left handlebar clutch lever 1 the clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting transmission gears. Squeezing the lever dise...

  • Page 38: Notice

    2-20 dimmer switch 3 “ ” position the headlight low beam and taillight turn on. “ ” position the headlight high beam and taillight turn on. The high beam indicator light also turns on. Notice holding the dimmer switch between the “ ” and “” position will light both the high and low headlight bea...

  • Page 39: Notice

    2-21 turn signal light switch “ ” 4 moving the switch to the “ ” position will flash the left turn signal. Moving the switch to the “ ” position will flash the right turn signal. The indicator light will also flash intermittently. To cancel turn signal opera- tion, push the switch on. Horn switc...

  • Page 40: Right Handlebar

    2-22 hazard warning switch “ ” 6 all four turn signal lights and indicators will flash simultaneously when the switch is turned on with the ignition switch in the “on” or “p” position. Use the hazard warning lights to warn other traffic during emergency parking or when your vehicle could other- wis...

  • Page 41:  Warning

    2-23 front brake lever 2 the front brake is applied by squeezing the brake lever gently toward the throttle grip. This motorcycle is equipped with disk brake system and excessive pressure is not required to slow the machine down properly. The brake light will come on when the lever is squeezed inwar...

  • Page 42

    2-24 electric starter switch “ ” 3 this switch is used for operating the starter motor. With the ignition switch in the “on” position, the engine stop switch in “ ”, the clutch disengaged, push the electric starter switch to operate the starter motor and start the engine. Note: this motorcycle is ...

  • Page 43: Notice

    2-25 throttle grip 4 engine speed is controlled by the position of the throttle grip. Turn it toward you to increase engine speed. Turn it away from you to decrease engine speed. Notice engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness fr...

  • Page 44: Fuel Tank Cap

    2-26 fuel tank cap to open the fuel tank cap, insert the ignition key into the lock and turn it clockwise. With the key inserted, lift the cap up with key. To close the fuel tank cap, push the cap down firmly with the key in the cap lock. Use fresh gasoline when filling up the fuel tank. Do not use ...

  • Page 45:  Warning

    2-27  warning if you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. Stop adding fuel when the fuel level reaches the bottom of the filler neck.  warning failure to follow safety precautions when refueling coul...

  • Page 46: Gearshift Lever

    2-28 gearshift lever this motorcycle has a 5-speed transmission which operates as shown. To shift properly, squeeze the clutch lever and close the throt- tle at the same time you operate the gear- shift lever. Lift the front end of the gear shift lever or depress the rear end of the gearshift lever ...

  • Page 47: Rear Brake Pedal

    2-29 note: when the transmission is in neutral, the green indicator light on the instrument panel will be lit. However, even though the light is lit, cautiously and slowly release the clutch lever to make sure that the transmis- sion is positively in neutral. Reduce your road speed before down-shift...

  • Page 48: Helmet Holder

    2-30 helmet holder vl1500b vl1500t/bt the helmet holder is located on the left side below the rear seat. Insert the key and turn it clockwise to open the latch. Hook your hel- met fastener ring to the latch and turn the key back to lock the holder. (vl1500t/bt) note: the tool box is equipped with th...

  • Page 49: Side Stand

    2-31 side stand this motorcycle is equipped with a side stand to support the motorcycle when park- ing. An interlock system is provided to cut off the ignition circuit when the side stand is down and the transmission is in any gear other than neutral. The side stand/ignition interlock system works a...

  • Page 50: Sidecase (Vl1500T/bt)

    2-32 sidecase (vl1500t/bt) notice if you do not take proper precautions when parking, the motorcycle can fall over. Park the motorcycle on firm, level ground whenever possible. If you must park on an incline, aim the front of the motorcycle uphill and put the transmis- sion into 1st gear to reduce t...

  • Page 51

    2-33 to open the sidecase: insert the ignition key into the lock and turn it counterclockwise to open the lid. Note: • if it is hard to lock or unlock the sidecase lid with a spare key without a key cover, use a key with a key cover. • if the lock is frozen, pour warm water around the lock to melt t...

  • Page 53

    3-1 3 fuel, oil and coolant recommendations fuel octane rating ............................................................................................................................ 3-2 oxygenated fuel recommendation ................................................................................

  • Page 54: Fuel Octane Rating

    3-2 fuel, oil and coolant recommendations fuel octane rating use unleaded gasoline with an octane rating of 91 or higher (research method). Unleaded gasoline can extend spark plug life and exhaust components life. (canada) your motorcycle requires unleaded gasoline with a minimum pump octane rating ...

  • Page 55

    3-3 oxygenated fuel recommendation (canada, eu) oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your motor- cycle without jeopardizing the new vehicle limited warranty or the emission control system warranty. Note: oxygenated fuels are f...

  • Page 56: Notice

    3-4 note: • to help minimize air pollution, suzuki recommends that you use oxygenated fuels. • be sure that any oxygenated fuel you use has recommended octane ratings. • if you are not satisfied with the drivability of your motorcycle when you are using an oxygenated fuel, or if engine pinging is ex...

  • Page 57: Engine Oil

    3-5 engine oil use suzuki genuine engine oil or equivalent. If suzuki genuine engine oil is not available, select a proper engine oil according to the following guideline. Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use oil with an...

  • Page 58

    3-6 jaso t903 the jaso t903 standard is an index to select engine oils for 4-stroke motorcycle and atv engines. Motorcycle and atv engines lubricate clutch and transmission gears with engine oil. Jaso t903 specifies performance requirements for motorcycle and atv clutches and transmissions. There ar...

  • Page 59: Final Gear Oil

    3-7 api sg, sh, sj or sl recommended api sh, sj or sl not recommended final gear oil use an sae90 hypoid gear oil which is rated gl-5 under the api classification system. If you operate the motorcycle where ambient temperature is below 0°c (32°f), use an sae80 hypoid gear oil. A pi service sj sae 10...

  • Page 60: Engine Coolant Solution

    3-8 engine coolant solution use “suzuki super long life cool- ant” or “suzuki long life coolant”. If “suzuki super long life coolant” and “suzuki long life coolant” are not available, use a glycol-based antifreeze compatible with an aluminum radiator mixed with distilled water only at the ratio of 5...

  • Page 61: Notice

    3-9 engine coolant engine coolant performs as a rust inhibitor and water pump lubricant as well as an anti- freeze solution. Therefore engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to the freezing point. Suzuki super long life coolan...

  • Page 62

    3-10 suzuki long life coolant (green) water for mixing use distilled water only. Water other than distilled water can corrode and clog the alu- minium radiator. Required amount of water/coolant solution capacity (total): 2700 ml (2.9/2.4 us/imp. Qt) note: this 50% mixture will protect the cooling sy...

  • Page 63: Break-In (Running-In) and

    4-1 4 break-in (running-in) and inspection before riding maximum throttle opening recommendation ......................................................................... 4-2 vary the engine speed ..........................................................................................................

  • Page 64: Maximum Throttle Opening

    4-2 break-in (running-in) and inspection before riding the opening explains how important proper break-in is to achieve maximum life and per- formance from your new suzuki. The follow- ing guidelines explain proper break-in procedures. Maximum throttle opening recommendation this table shows the max...

  • Page 65: Breaking In The New Tire

    4-3 breaking in the new tire new tires need proper break-in to assure maximum performance, just as the engine does. Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km (100 miles) before attempt- ing maximum performance. Avoid hard acceleration, hard co...

  • Page 66: Before Riding

    4-4 allow the engine oil to circulate before riding allow sufficient idling time after warm or cold engine startup before applying load or rev- ving the engine. This allows time for the lubricating oil to reach all critical engine components. Observe your first and most critical service the initial ...

  • Page 67: Inspection Before Riding

    4-5 inspection before riding  warning failure to inspect your motorcycle before riding and to properly maintain your motorcycle increases the chances of an accident or equipment damage. Always inspect your motorcycle each time you use it to make sure it is in safe operating condition. Refer to the ...

  • Page 68: Warning

    4-6 before riding the motorcycle, be sure to check the following items. Never underesti- mate the importance of these checks. Per- form all of them before riding the machine. warning checking maintenance items when the engine is running can be hazardous. You could be severely injured if your hands ...

  • Page 69

    4-7 tires (  6-57) • correct pressure • adequate tread depth • no cracks or cut engine oil (  6-30) correct level cooling system (  6-44) • proper coolant level • no leaks or damage gear oil (  6-47) correct level horn (  2-21) correct function engine stop switch (  2-22) correct function ligh...

  • Page 71: Riding Tips

    5-1 5 riding tips starting the engine ........................................................................................................................... 5-2 starting off ............................................................................................................................

  • Page 72: Starting The Engine

    5-2 riding tips starting the engine before attempting to start the engine make sure: • the transmission is in neutral. • the engine stop switch is in the “ ” position. Note: this motorcycle is equipped with interlock system for the ignition circuit and the starter circuit. The engine can only be st...

  • Page 73:  Warning

    5-3 when the engine is hard to start: open the throttle 1/8 to 1/4 turn and push the electric starter switch.  warning exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury. ...

  • Page 74: Starting Off

    5-4 starting off  warning riding at excessive speeds increases your chances of losing control of the motorcycle, which can result in an acci- dent. Always ride at a speed that is proper for the terrain, visibility and operating con- ditions, and your skills and experience.  warning if you remove e...

  • Page 75:  Warning

    5-5 after moving the side stand to the fully up position, squeeze the clutch lever in and pause momentarily. Engage first gear by depressing the gearshift lever downward. Turn the throttle grip a little toward you and at the same time release the clutch lever gently and smoothly. As the clutch engag...

  • Page 76: Using The Transmission

    5-6 using the transmission the transmission is provided to keep the engine operating smoothly in its normal operating speed range. The gear ratios have been carefully chosen to meet the charac- teristics of the engine. The rider should always select the most suitable gear for the prevailing conditio...

  • Page 77:  Warning

    5-7  warning downshifting when engine speed is too high can; • cause the rear wheel to skid and lose traction due to increased engine brak- ing, resulting in an accident; or • force the engine to overrev in the lower gear, resulting in engine dam- age. Reduce speed before downshifting.  warning do...

  • Page 78: Riding On Hills

    5-8 riding on hills • when climbing steep hills, the motorcy- cle may begin to slow down and show lack of power. At this point you should shift to a lower gear so that the engine will again be operating in its normal power range. Shift rapidly to prevent the motorcycle from losing momentum. • when r...

  • Page 79:  Warning

    5-9  warning inexperienced riders tend to underuti- lize the front brake. This can cause excessive stopping distance and lead to a collision. Using only the front or rear brake can cause skidding and loss of control. Apply both brakes evenly and at the same time.  warning hard braking while turnin...

  • Page 80: Notice

    5-10 5. Park the motorcycle on a firm, flat sur- face where it will not fall over. Notice holding the motorcycle stopped with throttle and clutch lever operation on inclines can damage motorcycle’s clutch. Use the brakes when stopping the motorcycle on inclines.  caution a hot muffler can cause sev...

  • Page 81

    5-11 note: if the motorcycle is to be parked on the side stand on a slight slope, the front end of the motorcycle should face “up” the incline to avoid rolling forward off the side stand. You may leave the motorcycle in 1st gear to help prevent it from rolling off the side stand. Shift to neutral be...

  • Page 82: Carrying A Passenger

    5-12 carrying a passenger before you invite someone to be a passen- ger on your motorcycle, you need to be thor- oughly familiar with motorcycle operation. Adjust tire pressures and suspension according to the tire pressure and loading section and the suspension section of this manual. The passenger...

  • Page 83: Inspection and Maintenance

    6-1 6 inspection and maintenance maintenance schedule ..................................................................................................................... 6-2 tools .........................................................................................................................

  • Page 84: Maintenance Schedule

    6-2 inspection and maintenance maintenance schedule the chart indicates the intervals between periodic services in miles, kilometers and months. At the end of each interval, be sure to inspect, check, lubricate and service as instructed. If your motorcycle is used under high stress conditions such a...

  • Page 85:  Warning

    6-3 note: the maintenance chart speci- fied the minimum requirements for mainte- nance. If you use your motorcycle under severe conditions, perform maintenance more often than shown in the chart. If you have any questions regarding maintenance intervals, consult your suzuki dealer or a qualified mec...

  • Page 86

    6-4 maintenance chart interval: this interval should be judged by number of months or odometer reading, whichever comes first. Interval months 2 12 24 36 48 km 1000 6000 12000 18000 24000 item miles 600 4000 7500 11000 14500 air cleaner element (  6-17) – – – i – replace every 36000 km (22000 miles...

  • Page 87

    6-5 note: i= inspect and clean, adjust, replace or lubricate as necessary, r= replace, t= tighten interval months 2 12 24 36 48 km 1000 6000 12000 18000 24000 item miles 600 4000 7500 11000 14500 * radiator hose (  6-46) – i i i i final gear oil (  6-47) r – i – i clutch cable play (  6-42) – i i...

  • Page 88

    6-6 for europe and oceania countries interval months 2 12 24 36 48 km 1000 12000 24000 36000 48000 item miles 600 7500 15000 22500 30000 air cleaner element (  6-17) – – – i – replace every 36000 km (22000 miles) * exhaust pipe bolts and muffler bolts t t t t t * valve clearance i inspect every 120...

  • Page 89

    6-7 note: i and inspect= inspect and clean, adjust, replace or lubricate as necessary; r= replace; t= tighten interval months 2 12 24 36 48 km 1000 12000 24000 36000 48000 item miles 600 7500 15000 22500 30000 * radiator hose (  6-46) – i i i i final gear oil (  6-47) r – i – i clutch cable play (...

  • Page 90

    6-8.

  • Page 91: Tools

    6-9 tools a tool kit is provided with your motorcycle. The tool box is located on the left side of the motorcycle. 1. Unhook the hooks and remove the cover. 2. To open the tool box, insert the ignition key into the lock and turn it counterclock- wise..

  • Page 92: Lubrication Points

    6-10 lubrication points proper lubrication is important for smooth and long life of each working part of your motorcycle and also for safe riding. It is a good practice to lubricate the machine after a long rough ride and after it gets wet in the rain or after washing it. Major lubrication points ar...

  • Page 93: Battery

    6-11 1 clutch lever pivot 2 gearshift link pivots 3 side stand pivot and spring hook 4 brake lever pivot 5 throttle cable 6 brake pedal pivot battery the battery on this motorcycle is a sealed type battery and requires no maintenance of fluid level and specific gravity. But have your authorized suzu...

  • Page 94:  Warning

    6-12  warning diluted sulfuric acid from the battery can cause blindness or severe burns. When working near the battery, use proper eye protection and gloves. Flush eyes or body with ample water and get medical care immediately if you suffer injury. Keep batteries out of reach of children.  warnin...

  • Page 95

    6-13 battery removal to remove the battery, follow the procedure below: 1. Place the motorcycle on the side stand. 2. Remove the bolt 1. 3. Push down the front end of the rear seat 2 and pull the seat backward..

  • Page 96

    6-14 4. Remove the bolts and seat band 3. To remove the front seat 4, raise the rear end of the front seat and slide it back- ward. 5. Disconnect the negative (–) terminal 5. 6. Remove the cap. Disconnect the positive (+) terminal 6. 7. Remove the battery 7..

  • Page 97: Notice

    6-15 to install the battery: 1. Install the battery in the reverse order of removal. 2. Connect the battery terminals securely. Note: • select the same type mf battery when replacing the battery. • recharge the battery once a month if the motorcycle is not used for a long time. Notice reversing the ...

  • Page 98

    6-16 the crossed-out wheeled bin symbol a located on the battery label indicates that used battery should be collected separately from ordinary household waste. The chemical symbol of “pb” b indicates the battery contains more than 0.004% lead. By ensuring the used battery is disposed of or recycled...

  • Page 99: Air Cleaner

    6-17 air cleaner if the elements have become clogged with dust, intake resistance will increase with a resultant decrease in power output and an increase in fuel consumption. If you use your motorcycle under normal low-stress condi- tions, you should service the air cleaner at the intervals specifie...

  • Page 100: Notice

    6-18 air cleaner element removal 1. Place the motorcycle on the side stand. Remove the fuel tank by referring to the fuel hose section. Right notice failure to inspect the air cleaner element frequently if the vehicle is used in dusty, wet, or muddy conditions can damage your motorcycle. The air cle...

  • Page 101

    6-19 left 2. Loosen the clamp bolt. 3. Remove the bolts. Unhook the hook. 4. Remove the air cleaner case 1 with the joint tube..

  • Page 102

    6-20 right left 5. Remove the screws. Remove the air cleaner case 2..

  • Page 103

    6-21 right left 6. Remove the screws. Remove the air cleaner element 3..

  • Page 104: Notice

    6-22 7. Inspect the air cleaner element condi- tion. Replace the air cleaner element periodically. 8. Reinstall the air cleaner element in reverse order of removal. Be sure that the air cleaner element is securely in position and is properly sealed. Notice compressed air can damage the air cleaner e...

  • Page 105: Notice

    6-23 right left 9. When installing the air cleaner case, align the marks the air cleaner joint tube and the air cleaner chamber. Note: be careful not to spray water on the air cleaner box when cleaning the motorcy- cle. Reinstall the fuel tank. Note: check that the fuel tank drain hose and breather ...

  • Page 106

    6-24 air cleaner drain plug right left.

  • Page 107: Spark Plugs

    6-25 remove the plug and drain water and oil at the periodic maintenance interval. The air cleaner drain plugs are located inside the air cleaner box and air cleaner left chamber side. Spark plugs spark plug removal 1. Place the motorcycle on the side stand..

  • Page 108

    6-26 front rear.

  • Page 109

    6-27 2. Unhook the hooks and pull off the cover. 3. Pull off the spark plug caps. 4. Remove the spark plugs with a spark plug wrench. Spark plug inspection 0.8 – 0.9 mm (0.031 – 0.035 in) readjust the spark plug gap to 0.8 – 0.9 mm (0.031 – 0.035 in) with a spark plug gap thickness gauge. The spark ...

  • Page 110: Notice

    6-28 before removing the carbon deposits, observe the color of the porcelain tip of each spark plug. This color tells you whether or not the standard spark plug is suitable for your type of usage. A normally-operating spark plug should be light brown in color. If the spark plug is white or glazed ap...

  • Page 111: Notice

    6-29 note: this motorcycle uses a resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interference with your motorcycle’s ignition system, resulting in motorcycle performance problems. Use only the recommended spark plugs. Installation ngk d...

  • Page 112: Engine Oil

    6-30 engine oil long engine life depends much on the selection of a quality oil and the periodic changing of the oil. Daily oil level checks and periodic changes are two of the most impor- tant maintenance items to be performed. Engine oil level check notice dirt can damage the moving engine parts o...

  • Page 113:  Caution

    6-31 check the engine oil level with the engine oil dipstick. The dipstick comes out together with the oil filler cap as shown. The level on the dipstick should be between the “l” (low) and “f” (full) lines. The engine oil level inspection should be performed under the following conditions: 1. Place...

  • Page 114: Notice

    6-32 engine oil and filter change change the engine oil and oil filter at the scheduled time. The oil should be changed when the engine is warm so that the oil will drain thoroughly from the engine. The pro- cedure is as follows: 1. Place the motorcycle on the side stand. 2. Remove the oil filler ca...

  • Page 115:  Caution

    6-33 3. Place a drain pan under the drain plug. 4. Remove the drain plug 2 and gasket 3 from the bottom of the engine and drain the engine oil into a drain pan.  caution hot engine oil and exhaust pipes can burn you. Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare...

  • Page 116:  Warning

    6-34 note: recycle or properly dispose of used oil. Oil filter wrench (part no. 09915-40620)  warning children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with oil may irritate skin. Keep new and used oi...

  • Page 117

    6-35 5. Turn the oil filter 4 counterclockwise and remove it with a suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. 6. Wipe off the mounting surface 5 on the engine where the new filter will be seated with a clean rag..

  • Page 118: Notice

    6-36 7. Smear a little engine oil around the rub- ber gasket 6 of the new oil filter. 8. Screw the new filter by hand until the fil- ter gasket contacts the mounting surface (a small resistance will be felt). Note: to tighten the oil filter properly, it is important to accurately identify the positi...

  • Page 119

    6-37 9. Mark the top dead center position on the “cap type” filter wrench or on the oil filter. Use an oil filter wrench to tighten the fil- ter 2 turns or to specified torque. Oil filter tightening torque: 20 n·m (2.0 kgf-m, 14.5 lbf-ft) 10. Replace the drain plug gasket 3 with a new one. Reinstall...

  • Page 120: Throttle Cable Adjustment

    6-38 11. Check the oil level according to oil level check procedure. Note: check to see that no oil is leaking from the oil filter cover. Throttle cable adjustment 2.0 – 4.0 mm (0.08 – 0.16 in) notice engine damage may occur if you use oil that does not meet suzuki’s specifica- tions. Be sure to use...

  • Page 121:  Warning

    6-39 to adjust the cable play: 1. Loosen the lock nut 1. 2. Turn the adjuster 2 so that the throttle grip has 2.0 – 4.0 mm (0.08 – 0.16 in) play. 3. Tighten the lock nut 1. Throttle cable boots the throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the bo...

  • Page 122: Engine Idle Speed Inspection

    6-40 engine idle speed inspection inspect the engine idle speed. The engine idle speed should be 900 – 1100 r/min when the engine is warm. Note: if the engine idle speed is not within the specified range, ask your suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. Fuel hose ...

  • Page 123

    6-41 3. Disconnect the coupler 1 and remove the instrument panel assembly 2. 4. Remove the bolt 3. Raise the rear end of the fuel tank and slide it backward..

  • Page 124: Clutch Adjustment

    6-42 5. Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. Note: lifting up the fuel tank too much can result in the fuel hose becoming bent or twisted. Lift the fuel tank as little as possible and disconnect the fuel hose. The fuel tank in t...

  • Page 125

    6-43 major adjustment 1. Remove the 3 bolts. Remove the cover. 2. Loosen the lock nuts 3 and turn the nuts to obtain the correct clutch lever play. 3. Minor adjustment can be made with the clutch lever side adjuster 1. 4. Tighten the lock nuts 2 and 3..

  • Page 126: Coolant

    6-44 note: check that the clearance between the clutch cable and gearshift rod is more than 6 mm (0.2 in) before tightening the lock nuts 3. Note: any maintenance of the clutch other than the clutch cable play adjustment should be performed by your suzuki dealer. Coolant coolant level the engine coo...

  • Page 127

    6-45 note: • check the coolant level when the engine is cold. • if the engine coolant reservoir is empty, check the radiator coolant level. To add specified engine coolant: 1. Place the motorcycle on the side stand. 2. Remove the bolts and left side lower cover. 3. Remove the filler cap and add spec...

  • Page 128:  Warning

    6-46 note: adding only water will dilute the engine coolant and reduce its effectiveness. Add specified engine coolant. Changing the coolant change the coolant periodically. Note: about 2700 ml (2.9/2.4 us/imp. Pt) of coolant will required when filling the radia- tor and reservoir tank. Radiator hos...

  • Page 129: Final Gear Oil

    6-47 final gear oil change the gear oil at initial 1000 km (600 miles) and inspect every 12000 km (7500 miles). Use sae90 hypoid gear oil which is rated gl-5 under api classification system. If you operate the motorcycle where ambient temperature is below 0°c (32°f) use sae 80 hypoid gear oil. The p...

  • Page 130:  Warning

    6-48 note: recycle or properly dispose of used oil.  warning operating the motorcycle with too little final gear oil can cause the final drive unit to lock up and cause an accident. Check for leaks and the correct level of final gear oil before each use. Add oil if necessary. Tighten the drain plug...

  • Page 131: Brakes

    6-49 brakes this motorcycle utilizes front and rear disk brakes. Proper operation of brake systems are vital to safe riding. Be sure to perform the brake inspection as scheduled. Brake system inspect your brake system for the following items daily: • inspect the fluid level in the reservoirs. • insp...

  • Page 132

    6-50 brake fluid front rear check the brake fluid level in both the front and rear brake fluid reservoirs. Inspect for brake pad wear and leaks..

  • Page 133:  Warning

    6-51  warning brake fluid will gradually absorb mois- ture through the brake hoses. Brake fluid with high water content lowers the boil- ing point and can cause brake system malfunction due to corrosion of brake components. Boiling brake fluid or brake system malfunction could result in an accident...

  • Page 134:  Warning

    6-52  warning brake fluid is harmful or fatal if swal- lowed, and harmful if it comes in contact with skin or eyes. Solution can be poi- sonous to animals. If brake fluid is swallowed, do not induce vomiting. Immediately contact a poison control center or a physician. If brake fluid gets in eyes, f...

  • Page 135

    6-53 brake pads front rear inspect the front and rear brake pads by not- ing whether or not the friction pads are worn down to the grooved wear limit line 1. If a front or rear pad is worn to the grooved wear limit line both front or both rear pads must be replaced with new ones by your autho- rized...

  • Page 136:  Warning

    6-54 note: do not squeeze/depress the brake lever/pedal when the pads are not in their positions. It is difficult to push the pistons back and brake fluid leakage may result.  warning failure to inspect and maintain the brake pads and replace them when recom- mended can increase your chance of havi...

  • Page 137:  Warning

    6-55 rear brake pedal adjustment the rear brake pedal position must be prop- erly adjusted at all times or the disk brake pads will rub against the disk causing dam- age to the pads and to the disk surface. Adjust the brake pedal position in the follow- ing manner:  warning replacing only one of th...

  • Page 138: Notice

    6-56 110 – 120 mm (4.3 – 4.7 in) 1. Loosen the lock nut 1, and turn the push rod 2 to locate the pedal 110 – 120 mm (4.3 – 4.7 in) above the top face of the footrest. 2. Retighten the lock nut 1 to secure the push rod 2 in the proper position. Notice an incorrectly adjusted brake pedal may force bra...

  • Page 139: Tires

    6-57 rear brake light switch to adjust the brake light switch, hold the switch body and turn the adjuster so that the brake light will come on just before a pres- sure rise is felt when the brake pedal is depressed. Tires  warning the tires on your motorcycle form the crucial link between your moto...

  • Page 140:  Warning

    6-58 tire pressure and loading proper tire pressure and proper tire loading are important factors. Overloading your tires can lead to tire failure and loss of motorcycle control. Check tire pressure each day before you ride, and be sure the pressure is correct for the motorcycle load according to th...

  • Page 141

    6-59 cold tire inflation pressure under-inflated tires make smooth cornering difficult, and can result in rapid tire wear. Over-inflated tires cause smaller amount of tire to be in contact with the road, which can contribute to skidding and loss of control. Note: when you detect drops in tire pres- ...

  • Page 142

    6-60 tire condition and type proper tire condition and proper tire type affect motorcycle performance. Cuts or cracks in the tires can lead to tire failure and loss of motorcycle control. Worn tires are susceptible to puncture failures and subse- quent loss of motorcycle control. Tire wear also affe...

  • Page 143:  Warning

    6-61 always balance the wheel after repairing a puncture or replacing the tire. Proper wheel balance is important to avoid variable wheel- to-road contact, and to avoid uneven tire wear. Front rear size 130/80r17m/c 65h 200/60r16m/c 79h type bridgestone g853 g bridgestone g852 g  warning an imprope...

  • Page 144:  Warning

    6-62  warning failure to follow the instructions below for tubeless tires may result in an acci- dent due to tire failure. Tubeless tires require different service procedures than tube tires. • tubeless tires require an air-tight seal between the tire bead and wheel rim. Special tire irons and rim ...

  • Page 145: System

    6-63 side stand/ignition interlock system check the side stand/ignition interlock sys- tem for proper operation as follows: 1. Sit on the motorcycle in the normal riding position, with the side stand up. 2. Shift into first gear, hold the clutch in, and start the engine. 3. While continuing to hold ...

  • Page 146: Front Wheel Removal

    6-64 front wheel removal 1. Place the motorcycle on the side stand. 2. Loosen the axle holder bolt 1 on the right front fork. Loosen the axle shaft 2 temporarily. Note: a special tool is necessary to loosen the axle shaft 2. The special tool is avail- able from a suzuki dealer.  warning if the side...

  • Page 147: Notice

    6-65 3. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end. Carefully position a jack under the engine or chassis tubes and raise the jack until the front wheel is slightly off the ground. 4. Turn the axle counterclockwise and draw it out. Notice imprope...

  • Page 148:  Warning

    6-66 5. Slide the front wheel forward. Note: never squeeze the front brake lever with the front wheel removed. It is very diffi- cult to force brake pads into the caliper assembly. 6. To reinstall the wheel assembly, reverse the sequence described above. 7. After installing the wheel, apply the fron...

  • Page 149: Rear Wheel Removal

    6-67 front axle tightening torque: 100 n·m (10.0 kgf-m, 72.5 lbf-ft) front axle holder bolt tightening torque: 33 n·m (3.3 kgf-m, 24.0 lbf-ft) rear wheel removal  warning if the bolts and nuts are not properly tightened, the wheel can come off, caus- ing an accident. Be sure to tighten the bolts an...

  • Page 150

    6-68 1. Place the motorcycle on the side stand. 2. (vl1500t/bt) open the right sidecase by referring to the sidecase section. Remove the bolts and right sidecase. 3. (vl1500t/bt) remove the bolts and sidecase brace 1 and 2..

  • Page 151:  Caution

    6-69 4. Remove the cap. 5. Remove the axle nut 3.  caution a hot muffler can burn you. Wait until the muffler cools before removing the axle nut..

  • Page 152

    6-70 6. Place an accessory service stand or equivalent under the swingarm or chas- sis tubes to stabilize the rear end. 7. Draw out the axle. 8. Remove the brake caliper bracket mounting bolt 4. Remove the brake cali- per assembly 5..

  • Page 153:  Warning

    6-71 9. Remove the wheel from the splined drive gear and set the wheel assembly on the ground. 10. Remove the rear wheel assembly. 11. To replace the wheel reverse the com- plete sequence listed. Rear axle tightening torque: 100 n·m (10.0 kgf-m, 72.5 lbf-ft) rear brake caliper bracket mounting bolt ...

  • Page 154: Light Bulb Replacement

    6-72 light bulb replacement the wattage rating of each bulb is shown on the chart below. When replacing a burned out bulb, always use the exact same wattage rating. Using other than the specified rating can result in overloading the electrical sys- tem or premature failure of a bulb. Notice failure ...

  • Page 155

    6-73 headlight to replace the headlight bulb, follow the pro- cedure below: 1. Remove the right and left bolts. Unhook the hooks. Remove the headlight cover 1. 2. Remove the bolts. Unhook the hooks. Remove the headlight assembly 2..

  • Page 156

    6-74 3. Disconnect the socket 3 from the head- light and remove the rubber cap 4. 4. Unhook the bulb holder spring 5, and pull out the bulb 6..

  • Page 157: Notice

    6-75 5. To replace the headlight bulb, reverse the above sequence. Position light (if equipped) 1. Pull out the socket. Notice the headlight bulb’s life may be short- ened by oil from your fingers if you touch it. When replacing the headlight bulb, be careful not to touch the glass. Grasp the new bu...

  • Page 158

    6-76 2. Pull off the bulb from the socket. Headlight beam adjustment the headlight beam can be adjusted both up and down or right and left if necessary. To adjust the beam up and down: turn the adjuster 1 clockwise or counter- clockwise..

  • Page 159

    6-77 to adjust the beam right and left: turn the adjuster 2 clockwise or counter- clockwise. Turn signal lights to replace the turn signal light bulbs, follow the procedure below: 1. Remove the screw 1. 2. Turn the lens counterclockwise and remove it..

  • Page 160: Notice

    6-78 3. Push in on the bulb 2, turn it to the left and pull it out. 4. To fit the replacement bulb, push it in and turn it to the right while pushing. Notice overtightening the screws when rein- stalling the lens may cause the lens to crack. Tighten the screws only until they are snug..

  • Page 161

    6-79 license plate light to replace the license plate light bulb, follow the procedure steps: 1. Turn the license plate lens counterclock- wise and remove it. 2. Pull off the bulb from the socket..

  • Page 162: Fuses

    6-80 fuses if something electrical on your motorcycle stops working, the first thing you should check for is a blown fuse. The electrical cir- cuits on the motorcycle are protected from overload by fuses in the circuits. If a blown fuse is found, then the electrical problem must be inspected and rep...

  • Page 163

    6-81 main fuse the main fuse is located under the front seat. One 30a spare fuse is located in the fuse box. Fuses the fuses are located under the front seat. Two spare fuses (10a and one 15a) are pro- vided in the fuse box..

  • Page 164: Catalytic Converter

    6-82 fuse list • 30a main fuse protects all electrical cir- cuits. • 10a head-hi fuse protects the speed- ometer and headlight high beam. • 10a head-lo fuse protects the head- light low beam. • 15a ignition fuse protects the head- light relay, fan motor relay, side stand relay, oxygen sensor, soleno...

  • Page 165: Notice

    6-83 notice improper motorcycle operation can cause catalyst or other motorcycle dam- age. To avoid damage to the catalyst or other related components, you should take the following precautions: • maintain the engine in the proper oper- ating condition. • in the event of an engine malfunction, parti...

  • Page 166:  Warning

    6-84  warning if you park or operate the motorcycle in areas where there are combustible mate- rials such as dry grass or leaves, these materials may come in contact with the catalytic converter or other hot exhaust components. This can cause a fire. Avoid parking or operating your vehicle in areas...

  • Page 167: Troubleshooting

    7-1 7 troubleshooting fuel supply check .............................................................................................................................. 7-2 ignition system check ..............................................................................................................

  • Page 168: Fuel Supply Check

    7-2 troubleshooting this troubleshooting guide is provided to help you find the cause of some common complaints. If the engine refuses to start perform the fol- lowing inspections to determine the cause. Fuel supply check if the fuel injection indicator displays “fi”, showing signs of trouble in the...

  • Page 169: Ignition System Check

    7-3 ignition system check 1. Remove spark plugs and reattach them to the spark plug caps. 2. Hold the spark plug firmly against the engine and push the starter switch with the ignition switch in the “on” position, the engine stop switch in the “ ” posi- tion, the transmission in neutral, and the cl...

  • Page 170: Engine Stalling

    7-4 engine stalling 1. Make sure there is enough fuel in the fuel tank. 2. If the fuel injection indicator displays “fi”, showing signs of trouble in the fuel injec- tion system, take your machine to an authorized suzuki dealer. Refer to the “instrument panel” section for an explanation of fuel inje...

  • Page 171: Storage Procedure and

    8-1 8 storage procedure and motorcycle cleaning storage procedure ........................................................................................................................... 8-2 procedure for returning to service ..........................................................................

  • Page 172: Storage Procedure

    8-2 storage procedure and motorcycle cleaning storage procedure if your motorcycle is to be left unused for an extended period of time, it needs special servicing requiring appropriate materials, equipment and skill. For this reason, suzuki recommends that you trust this maintenance work to your aut...

  • Page 173

    8-3 battery 1. Remove the battery from the motorcycle by referring to the battery section. 2. Clean the outside of the battery with a mild soap and remove corrosion from the terminals and wiring harness. 3. Store the battery in a room above freez- ing. Tires inflate the tires to the normal specifica...

  • Page 174: Procedure For Returning to

    8-4 procedure for returning to service 1. Clean the entire motorcycle. 2. Reinstall the battery by referring to the battery section. 3. Remove the spark plugs. Turn the engine a few times by putting the trans- mission in top gear and turning the rear wheel. Reinstall the spark plugs. 4. Drain the en...

  • Page 175

    8-5 how to help prevent corrosion • wash your motorcycle frequently, at least once a month. Keep your motorcy- cle as clean and dry as possible. • remove foreign material deposits. For- eign material such as road salt, chemi- cals, road oil or tar, tree sap, bird droppings and industrial fall-out ma...

  • Page 176: Motorcycle Cleaning

    8-6 motorcycle cleaning washing the motorcycle when washing the motorcycle, follow the instructions below: 1. Remove dirt and mud from the motorcy- cle with cool running water. You may use a soft sponge or brush. Do not use hard materials which can scratch the paint. 2. Wash the entire motorcycle wi...

  • Page 177: Notice

    8-7 3. Once the dirt has been completely removed, rinse off the detergent with running water. 4. After rinsing, wipe off the motorcycle with a wet chamois or cloth and allow it to dry in the shade. 5. Check carefully for damage to painted surfaces. If there is any damage, obtain “touch-up” paint and...

  • Page 178: Notice

    8-8 note: headlight lens can be fogged after washing the motorcycle or riding in a rain. Headlight fogging will be cleared gradually when the headlight is turned on. To clear the headlight lens fogging, run the engine to avoid battery discharge. Waxing the motorcycle after washing the motorcycle, wa...

  • Page 179: Inspection After Cleaning

    8-9 special care for matte finish paint do not use polishing compounds or waxes that contain polishing compounds on sur- faces which have a matte finish. The use of polishing compounds will change the appearance of the matte finish. Solid type waxes may be difficult to remove from surfaces with a ma...

  • Page 180: Specifications

    Specifications dimensions and curb mass overall length ....................................................................... 2570 mm (101.2 in) 2560 mm (100.8 in) ... Canada and australia overall width......................................................................... 990 mm (39.0 in) overal...

  • Page 181

    Drive train clutch ................................................................................... Wet multi-plate type transmission ........................................................................ 5-speed constant mesh gearshift pattern .....................................................

  • Page 182

    Electrical ignition type .......................................................................... Electronic ignition (transistorized) spark plug ............................................................................ Ngk cpr6ea-9 or denso u20epr9 battery ........................................

  • Page 183

    Capacities fuel tank............................................................................... 18.0 l (4.8/4.0 us/lmp. Gal) engine oil, without filter change .......................................... 3000 ml (3.2/2.6 us/lmp. Qt) with filter change .................................................

  • Page 184: Index

    Index a accessory use and motorcycle loading....................................................1-2 air cleaner..........................................6-17 allow the engine oil to circulate before riding .......................................4-4 avoid constant low speed .............4-3 b battery...

  • Page 185

    H helmet holder ...................................2-30 i ignition switch.....................................2-5 ignition system check ......................7-3 inspection after cleaning..............8-9 inspection before riding ................4-5 instrument panel ...............................2-...

  • Page 186

    N noise control system (australia only).................................1-10 o observe your first and most critical service .......................4-4 oxygenated fuel recommendation.................................3-3 p procedure for returning to service.................................................

  • Page 187

    S safe riding recommendation for motorcycle riders............................1-6 serial number location ...................1-8 side stand ............................................2-31 side stand/ignition interlock system ...................................................6-63 sidecase (vl1500t/b...

  • Page 191: Owner’S Manual

    99011-06j52-01a vl1500b/t/bt printed in japan part no. 99011-06j52-01a december, 2014 en vl1500b/t/bt owner’s manual l5 tk c © copyright suzuki motor corporation 2014 cyan magenta yellow black 8 mm vl1500b/t/bt (99011-06j52-01a) 4 /1 top 1st cover 4th cover.