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Suzuki Intruder VL800 Service Manual

Other manuals for Intruder VL800: Owner's Manual, Supplementary Service Manual

Summary of Intruder VL800

  • Page 1

    Group index general information 1 periodic maintenance 2 engine 3 shaft drive 4 fuel and lubrication system 5 cooling system 6 chassis 7 electrical system 8 servicing information 9 emission control information 10 revised 09/07.

  • Page 3: Supplements

    17 16 vl800/tk6 ('06- model) 15 vl800tk5 ('05- model) 14 vl800k5 ('05- model) 13 vl800k4 ('04- model) 12 vl800k3 ('03- model) 11 vl800k2 ('02- model) supplements vl800/c/tk9 (”09 model) 18 vl800/tk7 & tk8 ('07&’08- model) wiring diagram 19.

  • Page 4: How To  Use This  Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 5

    Symbol (for usa) listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise s...

  • Page 6

    Symbol (for the other countries) listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil un...

  • Page 7: General Information

    General information 1-1 contents general information 1.

  • Page 8: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ! Indicat...

  • Page 9

    General information 1-3 " * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * be sure to use special tools w...

  • Page 10: Serial Number Location

    1-4 general information serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right s de of the crankcase. These numbers are required especially for registering t...

  • Page 11

    General information 1-5 engine oil (for usa) suzuki recommends the use of suzuki performance 4 motor oil or an oil which is rated sf or sg under the api (american petroleum institute) service classification. The recom- mended viscosity is sae 10w/40. If an sae 10w/40 oil is not available, select an ...

  • Page 12: Break-In Procedures

    1-6 general information break-in procedures during manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performan...

  • Page 13: Information Labels

    General information 1-7 information labels no. Label or plate name applied specification e-02 e-03 e-19 e-24 e-28 e-33 1 noise label – – – 2 information label – – – 3 vacuum hose routing label – – – – – 4 fuel caution label – – – – 5 manual notice label – – – – 6 tire air pressure label 7 warning sa...

  • Page 14: Specifications

    1-8 general information specifications dimensions and dry mass overall length ................................................................ 2 510 mm (98.818 in) overall width ................................................................. 985 mm (38.779 in) overall height .........................

  • Page 15

    General information 1-9 chassis front suspension .......................................................... Telescopic, coil spring, oil damped rear suspension ........................................................... Link type, coil spring, oil damped, spring pre-load 7-way adjustable steering an...

  • Page 16: Country and Area Codes

    1-10 general information country and area codes the following codes stand for the applicable country(-ies) and area(-s). Code country or area e-02 england (uk) e-03 usa e-19 eu e-24 australia e-28 canada e-33 california.

  • Page 17: Periodic Maintenance

    Periodic maintenance 2-1 contents periodic maintenance 2.

  • Page 18

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, w...

  • Page 19

    Periodic maintenance 2-3 clutch lever holder gearshift link pivot side-stand pivot and spring hook throttle cable brake lever holder brake pedal pivot and brake rod link lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Majo...

  • Page 20: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Air cleaner • remove the screws and air cleaner case cover. • remove the air cleaner element. • carefully use air hose to blow the du...

  • Page 21

    Periodic maintenance 2-5 • remove the spark plug caps. • remove the spark plugs with a spark plug wrench. Heat range • check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one. If it is wh...

  • Page 22

    2-6 periodic maintenance spark plug and ignition coil/plug cap installation • install the spark plugs to the cylinder head with fingers, and then tighten them to the specified torque with a wrench. % spark plug: 11 n.M (1.1 kgf.M, 8.0 ib-ft) $ do not crossthread or over tighten the spark plug, or th...

  • Page 23

    Periodic maintenance 2-7 • remove all the inspection caps. • remove all the spark plugs. • remove the generator cover plug 3 and the timing inspection plug 4. • rotate the generator rotor to set the no.1 engine’s piston at tdc of the compression stroke. (rotate the rotor until the “r i t” line on th...

  • Page 24

    2-8 periodic maintenance front no. 2 engine no. 1 engine engine oil and oil filter engine oil replacement • keep the motorcycle upright. • place an oil pan below the engine, and drain oil by removing the oil drain plug 1 and filler cap 2. • start up the engine and allow it to run for several minutes...

  • Page 25

    Periodic maintenance 2-9 oil filter replacement • drain the engine oil as described in the engine oil replacement procedure. • remove the oil filter with the special tool. # 09915-40610: oil filter wrench • apply engine oil lightly to the gasket of the new oil filter before installation. • install t...

  • Page 26

    2-10 periodic maintenance fuel hose inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, replace the fuel hose. Engine idle speed note: warm up the engine before adjusting the engine idle speed. • start the engine, turn the throttle stop screw and set the engine idle spee...

  • Page 27

    Periodic maintenance 2-11 throttle cable play adjust the throttle cable play a as follows. Minor adjustment 1st step: • loosen the lock nut 1 of the throttle returning cable 2 and fully turn in the adjuster 3. 2nd step: • loosen the lock nut 4 of the throttle pulling cable 5. • turn the adjuster 6 i...

  • Page 28

    2-12 periodic maintenance major adjustment • remove the fuel tank. ( !5-3) • loosen the lock nuts 1 of the throttle returning cable 2. • turn the returning cable adjuster 3 to obtain proper cable play. • loosen the lock nuts 4 of the throttle pulling cable 5. • turn the pulling cable adjuster 6 in o...

  • Page 29

    Periodic maintenance 2-13 cooling system engine coolant level check • keep the motorcycle upright. • check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A full line b lower line • if the level is below the lower line, add engine coolant to the full l...

  • Page 30

    2-14 periodic maintenance air bleeding the cooling circuit • add engine coolant up to the radiator inlet. • support the motorcycle upright. • slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • add engine coolant up to the radiator inlet. • start up the en...

  • Page 31

    Periodic maintenance 2-15 final gear oil • keep the motorcycle upright. • place an oil pan under the final gear case. Remove the filler cap 1 and drain plug 2 to drain oil. • refit the drain plug 2. Pour the specified oil (sae 90 hypoid gear oil with gl-5 under api classification) through the filler...

  • Page 32

    2-16 periodic maintenance brake light switch • adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. Rear brake pedal height • loosen the lock nut 1. • adjust the brake pedal height a by turning the adjuster 2. " rear ...

  • Page 33

    Periodic maintenance 2-17 air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of air is...

  • Page 34

    2-18 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. " cold inflat...

  • Page 35

    Periodic maintenance 2-19 steering the steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support t...

  • Page 36

    2-20 periodic maintenance chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle. Item n.M kgf.M ib-ft 1 steering stem head nut 90 9.0 65.0 2 steering stem lock nut 80 8.0 58.0 3 front fork...

  • Page 37

    Periodic maintenance 2-21.

  • Page 38: Compression Pressure Check

    2-22 periodic maintenance overhaul the engine in the following cases: * compression pressure in one of the cylinders is less than 900 kpa (9 kgf/cm 2 , 128 psi). * the difference in compression pressure between any two cyl inders is more than 200 kpa (2 kgf/cm 2 , 28 psi). * all compression pressure...

  • Page 39: Oil Pressure Check

    Periodic maintenance 2-23 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification 350 – 650 kpa (3.5 – 6.5 kgf/cm 2 , 50 – 92 psi) at 3 000 r/min., oil temp. At 60°c (140°f) if the oil pressure i...

  • Page 40: Engine

    Engine 3-1 contents engine 3.

  • Page 41

    3-2 engine engine components removable with engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. Engine center parts removal installation inspection cap ...

  • Page 42

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure. • drain engine oil. ( !2-8) • drain ...

  • Page 43

    3-4 engine • disconnect the neutral switch lead wire coupler 1. • disconnect the generator lead wire coupler 2 and the signal generator lead wire coupler 3. • disconnect the side-stand switch lead wire coupler 4. • remove the clutch release mechanism. • remove the push rod. • remove the left footres...

  • Page 44

    Engine 3-5 • remove the air cleaner box bracket. • disconnect the negative pressure hose 1. • remove the carburetor. Caburetor removal !5-15 • remove the spark plug caps. • remove the right frame cover. • remove the no. 1 muffler..

  • Page 45

    3-6 engine • remove the no.2 exhaust pipe. • remove the rear clutch cover. • remove the cooling fan mounting bolts. • remove the engine mounting bolt 1. • remove the no. 1 exhaust pipe and the no. 2 muffler..

  • Page 46

    Engine 3-7 • remove the frame down tube. • support the engine with an engine jack. • remove the engine mounting bolts and nuts. • gradually lower the engine..

  • Page 47

    3-8 engine engine installation install the engine in the reverse order of engine removal. Pay attention to the following points: • install the universal joint. Note: be sure to face the short portion a backward when installing it. • install the boot. Note: make sure that the “up” mark b faces up. • ...

  • Page 48

    Engine 3-9 79 n.M (7.9 kgf.M, 57.0 lb-ft) 79 n.M (7.9 kgf.M, 57.0 lb-ft) 50 n.M (5.0 kgf.M, 36.0 lb-f ) 50 n.M (5.0 kgf.M, 36.0 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 25 n.M (2.5 kgf.M, 18.0 lb-ft) note: * the engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of...

  • Page 49

    3-10 engine • install the gearshift lever and the footrest in the correct posi- tion. " gearshift lever height a standard: 90 mm (3.5 in) • apply grease to the push rod and install it. # 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the others) • apply grea...

  • Page 50: Engine Disassembly

    Engine 3-11 engine disassembly • remove the pair pipes. • remove the spark plugs. % 09930-10121: spark plug wrench set • remove the valve timing inspection plug 1 and the generator cover cap 2. • position “rit” mark on the generator with the center of the valve timing inspection hole. Cylinder head ...

  • Page 51

    3-12 engine cylinder head/cylinder • loosen the water hose clamp screws. • remove the cylinder head bolts. (front cylinder) • remove the cylinder head and cylinder. (front cylinder) • after unlocking the ratchet, push the cam chain tension ad- juster rod fully. • insert the special tool between the ...

  • Page 52

    Engine 3-13 • remove the cylinder head bolt and nut. (rear cylinder) • push the cam chain tension adjuster rod and insert the special tool. % 09918-53810: chain tensioner lock tool • remove the cylinder head by removing the cylinder head bolts. • remove the water hose and pipe. • remove the cylinder...

  • Page 53

    3-14 engine starter motor • remove the starter motor cover. • remove the starter motor. Clutch • remove the clutch cover. • remove the clutch spring mounting bolts and springs diago- nally. • remove the pressure plate 1..

  • Page 54

    Engine 3-15 • remove the thrust washer 1, bearing 2, push piece 3 and push rod. • remove the clutch drive and driven plates. • remove the spring washer 4 and spring washer seat 5. • remove the clutch sleeve hub nut with the special tool. % 09920-53740: clutch sleeve hub holder • remove the washer 6 ...

  • Page 55

    3-16 engine • remove the primary driven gear assembly and the oil pump drive chain. • remove the thrust washer 1 and spacer 2. Oil pump • remove the oil pump by removing the circlip. % 09900-06107: snap ring pliers • remove the pin 1 and washer 2. Gearshift • draw out the gearshift shaft 1. • remove...

  • Page 56

    Engine 3-17 • remove the gearshift cam plate 1. • remove the gearshift cam stopper 2. Primary drive gear remove the primary drive gear by removing the primary drive gear bolt with the special tool. % 09930-40113: rotor holder & this bolt has left-hand thread. Turning it counter-clockwise may cause d...

  • Page 57

    3-18 engine neutral switch • remove the neutral switch assembly. • remove the oil pressure switch lead wire. Generator • remove the generator cover. • remove the starter motor driven gear and the idle gear. • loosen the generator rotor bolt. Note: when loosen the rotor bolt, do not remove it. The ro...

  • Page 58

    Engine 3-19 • remove the cam chain tensioner and the chain. Water pump • remove the water pump cover. • remove the water pump assembly. Secondary driven gear • remove the secondary driven gear housing bolts. • remove the secondary driven gear case..

  • Page 59

    3-20 engine • remove the secondary driven gear assembly. • remove the bearing 1. • remove the oil jet 2. Oil jet • remove the oil jets. Crankcase • remove the crankcase bolts. • separate the crankcase into two parts with the special tool. % 09920-13120: crankcase separator.

  • Page 60

    Engine 3-21 • remove the crankshaft. • remove the gearshift fork shafts and gearshift forks. • remove the transmission. Secondary drive bevel gear • remove the over driving gear 1 and bush 2. • remove the secondary drive bevel gear assembly..

  • Page 61: Engine Components Inspection

    3-22 engine engine components inspection and servicing cylinder head cover disassembly & be sure to identify each removed part as to its location, and lay the parts out in groups designated as “no.1 cyl- inder”, “no.2 cylinder”, “exhaust”, “intake”, so that each will be restored to the original loca...

  • Page 62

    Engine 3-23 "r" "f" camshaft the camshafts should be checked for wear and also for runout of cams and journals if the engine has been noted to produce ab- normal noise or vibration or to lack output power. Any of these malconditions could be caused by a worn camshafts. The camshaft can be distinguis...

  • Page 63

    3-24 engine if the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. " camshaft journal o.D. (sprocket side) : 24.959 – 24.980 mm (0.9826 – 0.9835 in) (other side)...

  • Page 64

    Engine 3-25 cylinder head valve and valve spring disassembly • using special tools, compress the valve springs and remove the two cotter halves 1 from valve stem. % 09916-14510: valve spring compressor 09916-14910: valve spring compressor attachment 09916-84511: tweezers • remove the valve spring re...

  • Page 65

    3-26 engine valve stem runout support the valve with “v” blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. " valve stem runout service limit: 0.05 mm (0.002 in) % 09900-20701: magnetic stand 09900-20606: dial gauge (1/100 mm) 09900-...

  • Page 66

    Engine 3-27 valve guide servicing • using the valve guide remover, drive the valve guide out to- ward the intake or exhaust rocker arm side. % 09916-44910: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement ...

  • Page 67

    3-28 engine 45˚ 15˚ valve seat exhaust valve seat width • coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold ...

  • Page 68

    Engine 3-29 • insert the solid pilot 1 (09916-24450: n-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and t-handle. Initial seat cut • using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • measure the valve seat width ...

  • Page 69

    3-30 engine bottom narrowing cut • if the contact area w is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. Final seat cut • if the contact area w is too low or too narrow, use the 45° cutter to raise and widen the contact area. Note: after cutting the 15°, ...

  • Page 70

    Engine 3-31 6.51 – 7.49 kgf (14.35 – 16.51 lbs) 32.5 mm (1.28 in) valve stem end condition inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the...

  • Page 71

    3-32 engine • insert the valves, with their stems coated with high quality mo- lybdenum disulfide lubricant (suzuki moly paste) all around and along the full stem length without any break. ' 99000-25140: suzuki moly paste & when inserting each valve, take care not to damage the lip of the stem seal....

  • Page 72

    Engine 3-33 15 mm (0.6 in) cylinder bore measure the cylinder bore diameter at six places. If any one of the measurements exceeds the limit, overhaul the cylinder and replace the piston with an oversize, or replace the cylinder. Once the reboring is done on any one cylinder which measurements is bey...

  • Page 73

    3-34 engine piston-to-cylinder clearance as a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. " piston to cylinder clearance service limit: 0.12 mm (0.0047 in)...

  • Page 74

    Engine 3-35 0.5 mm o.S. 1.0 mm o.S. Paint oil ring spacer oversize piston ring the following two types of oversize piston rings are used. They bear the following identification numbers. Size 1st 2nd 0.5 mm o.S. 50 50 1.0 mm o.S. 100 100 oversize oil ring the following two types of oversize oil rings...

  • Page 75

    3-36 engine 2nd ring 1st ring piston ring reassembly • install the piston rings in the order of oil ring, 2nd ring and 1st ring. • the first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. Note: side designations, top and bottom, are not appli...

  • Page 76

    Engine 3-37 conrod/crankshaft conrod small end i.D. Using a small bore gauge, measure the conrod small end inside diameter. ! Conrod small end i.D. Service limit: 20.040 mm (0.7890 in) " 09900-20602: dial gauge (1/1000 mm, 1 mm) 09900-22403: small bore gauge (18 – 35 mm) if the conrod small end insi...

  • Page 77

    3-38 engine • place plastigauge axially on the crank pin avoiding the oil hole, at tdc or bdc side as shown. • tighten the bearing cap with two-step torque values. Note: when fitting the bearing cap to crank pin, be sure to discriminate between its two ends, i.D. Code side and the other. I.D. Code a...

  • Page 78

    Engine 3-39 conrod i.D. Specification code 1 i.D. Specification 1 44.000 – 44.006 mm (1.7323 – 1.7325 in) 2 44.006 – 44.012 mm (1.7325 – 1.7328 in) 3 44.012 – 44.018 mm (1.7328 – 1.7330 in) crank pin o.D. Specification code 2 o.D. Specification 1 40.994 – 41.000 mm (1.6139 – 1.6142 in) 2 40.988 – 40...

  • Page 79

    3-40 engine conrod/crank pin bearing assembly • when fitting the bearing to the bearing cap and conrod, be sure to fix the stopper part 1 first and press in the other end. • apply molybdenum oil solution to the crank pin and bearing surface. % 99000-25140: suzuki moly paste • when mounting the conro...

  • Page 80

    Engine 3-41 • measure the crankshaft journal bearing i.D. 1 by using the special tool. ! Crankshaft journal bearing i.D. 1 standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in) " 09900-20508: cylinder gauge set if each crankshaft journal bearing i.D. Is not within the standard range, replace them with n...

  • Page 81

    3-42 engine crankshaft thrust clearance install the crankshaft in the right crankcase half after installing the thrust shim on the crankshaft. Note: the oil grooved face a of thrust shim 1 is faced to crankshaft web side. • place the thrust washer, camshaft drive sprocket and primary drive gear on t...

  • Page 82

    Engine 3-43 clutch clutch drive and driven plates note: wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one. ! Clutch drive plate thic...

  • Page 83

    3-44 engine generator/signal generator/ starter clutch generator stator and signal generator stator inspection &8-8, 19, 20 generator stator and signal generator stator servicing when replacing the generator stator or signal generator stator, route the wire properly. Starter clutch inspection instal...

  • Page 84

    Engine 3-45 starter clutch servicing • hold the rotor with off-set wrench and remove the starter clutch securing bolts. • when fitting the one way clutch to the guide 1, position flange side a of one way clutch to the rotor side. • apply thread lock super “1303” to the securing bolts and tighten the...

  • Page 85

    3-46 engine fwd transmission disassembly • disassemble the transmission gears as shown in the illustration. 1 driveshaft bolt 2 over driving gear 3 1st driven gear 4 4th driven gear 5 3rd driven gear 6 driveshaft 7 5th driven gear 8 2nd driven gear 9 counter haft/1st drive gear 0 4th drive gear a 3r...

  • Page 86

    Engine 3-47 reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to following points: note: always use new circlips. Note: before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. % 99000-25140: suzuki mo...

  • Page 87

    3-48 engine $ when installing the 1st and 3rd driven gear bushings, align the bushing oil hole with the driveshaft oil hole. Transmission gears and related parts.

  • Page 88

    Engine 3-49 gearshift fork gearshift fork to groove clearance using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance che...

  • Page 89

    3-50 engine crankcase oil sump filter • remove the oil sump filter cover. • remove the oil sump filter. • clean the oil sump filter using compressed air. • when installing the o-ring, apply grease to it. ( 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the o...

  • Page 90

    Engine 3-51 • when installing the oil pipe, use the new o-rings. • apply a small quantity of the thread lock “1342” to the oil pipe retainer bolts and tighten them securely. ) 99000-32050: thread lock “1342” oil pressure regulator • remove the oil pressure regulator. Check the operation of the oil p...

  • Page 91

    3-52 engine • remove the bearing with the special tool. " 09921-20220: bearing remover set note: if abnormal noise does not occur, it is not necessary to remove the bearing. Bearing reassembly • install the bearing into the crankcase with the special tool. " 09913-70210: bearing installer set oil pr...

  • Page 92: Engine Reassembly

    Engine 3-53 engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Secondary drive bevel gear • install the ...

  • Page 93

    3-54 engine crankshaft • install the thrust shim 1 on the crankshaft. Note: * the grooved face a of thrust shim 1 faces to crankshaft web side. * the thrust shim is selected by the crankshaft thrust clearance. ( &3-42) • install the crankshaft into the left crankcase half. Note: coat lightly moly pa...

  • Page 94

    Engine 3-55 • fit the gasket to the bolt a. • when securing the right and left crankcase halves, tighten each bolt a little at a time to equalize the pressure. Tighten all the securing bolts to the specified torque values. # crankcase 8mm bolt:(initial) 15 n.M (1.5 kgf.M, 11.0 lb-ft) (final) 22 n.M ...

  • Page 95

    3-56 engine • tighten the secondary gear case bolts to the specified torque. # secondary gear case bolt (initial): 15 n.M (1.5 kgf.M, 11.0 lb-ft) (final) : 22 n.M (2.2 kgf.M, 16.0 lb-ft) note: fit the washer to the bolt a. • tighten the secondary driven bevel gear bolt to the specified torque. Note:...

  • Page 96

    Engine 3-57 • install the new o-ring. • install the water pump cover. Note: fit the clamp to the bolt a. Cam chain/cam chain tensioner • install the cam chain tensioner and cam chain. # cam chain tensioner bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) 1 for front cylinder 2 for rear cylinder note: the no. 2 c...

  • Page 97

    3-58 engine • install the starter driven gear and the idle gear. • install the new gasket and dowel pins. • install the generator cover. Note: fit the new gaskets to the bolts a. Neutral switch • install the springs and switch contacts. • install the neutral switch. • install the oil pressure switch...

  • Page 98

    Engine 3-59 oil filter • apply engine oil lightly to the gasket of the oil filter before in- stallation. • install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface. Then tighten it 2 turns using the oil filter wrench. " 09915-40610: oil filter wren...

  • Page 99

    3-60 engine • install the cam driven gear 1 after installing the springs, pins and gearshift pawls. • install the cam guide and the pawl lifter. • apply a small quantity of thread lock “1342” to the nuts. ) 99000-32050: thread lock “1342” • install the gearshift return spring properly. • install the...

  • Page 100

    Engine 3-61 • install the oil pump driven gear and the circlip. " 09900-06107: snap ring pliers clutch • install the spacer 1 and the thrust washer 2. • engage the chain with the oil pump drive gear. • install the primary driven gear assembly and engage the chain with the oil pump driven gear. • app...

  • Page 101

    3-62 engine • install the washer 1 and the clutch sleeve hub nut 2. Note: the convex side of the washer faces outside. • tighten the clutch sleeve hub nut to the specified torque with the special tool. # clutch sleeve hub nut: 60 n.M (6.0 kgf.M, 43.5 lb-ft) " 09920-53740: clutch sleeve hub holder 95...

  • Page 102

    Engine 3-63 • install the wave washer seat 1 and the wave washer 2. • install the clutch drive plate no.2 a first. • install the drive and driven plate one by one into the clutch sleeve hub. • install the push rod. • install the clutch push piece 3, bearing 4 and thrust washer 5. • apply engine oil ...

  • Page 103

    3-64 engine • install the clutch cover and tighten the bolts. Note: fit the new gasket to the bolt a. Starter motor • install the starter motor. Note: apply grease to the new o-ring. ( 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the others) • install the ...

  • Page 104

    Engine 3-65 • place a cloth beneath the piston, and install the circlip 1. $ when turning the crankshaft, pull the cam chains up- ward, or the chains will be caught between the crank- case and the cam drive sprocket. Cylinder • install the cam chain tension adjuster to the cylinder. • after unlockin...

  • Page 105

    3-66 engine cylinder head • install the cam chain guide. 1 for front cylinder 2 for rear cylinder • fit the dowel pins and the new cylinder head gasket. $ use a new gasket to prevent gas leakage. • install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque. (rea...

  • Page 106

    Engine 3-67 front cylinder • assemble the front cylinder and the cylinder head. • tighten the cylinder head bolts and nut. # cylinder head bolt and nut (m8): 25 n.M (2.5 kgf.M, 18.0 lb-ft) • install the front cylinder assembly to the crankcase. • connect the water hoses. • tighten the cylinder head ...

  • Page 107

    3-68 engine camshaft pin bend up bolt washer sprocket • align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. Note: arrow marks are located to forward. • engage the chains on the cam sprockets with the locating pin holes a as shown in the pho...

  • Page 108

    Engine 3-69 1 6 1216 fwd front rear • apply suzuki bond “1216b” to the mating surface of the cyl- inder head cover. • fit the camshaft end caps 1. • apply grease to the o-ring 2 and install it. (front cylinder only) 1216 99000-31230: suzuki bond “1216b” ( 99000-25030: suzuki super grease “a” (for us...

  • Page 109

    3-70 engine front rear fwd 1216 1216 • remove the tensioner lock tools. Note: click sound is heard when the cam chain tension adjuster is re- leased. Location of cylinder head cover bolt note: * before installing the bolt 1, apply suzuki bond “1207b” to the thread of the bolt. * allen bolt: 2 * stai...

  • Page 110

    Engine 3-71 • install the intake pipe. • apply grease to the new o-ring and install the water outlet union. ( 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the others) • install the gasket and the breather cover. • apply grease to the new o-rings and instal...

  • Page 111

    3-72 engine • install the pair pipes. • install the head cover caps 1. • install the spark plugs. " 09930-10121: spark plug wrench set.

  • Page 112: Shaft Drive

    Shaft drive 4-1 contents shaft drive 4.

  • Page 113: Secondary Bevel Gears

    4-2 shaft drive *a secondary bevel gears construction 1 bush 2 overdriving driven gear 3 circlip 4 output cam dog 5 damper spring 6 secondary bevel gear set 7 shims (5 kinds) 8 driven bevel gear bearing 9 o-ring 0 shims (5 kinds) a o-ring b oil seal housing c oil seal d bearing stopper e universal j...

  • Page 114

    Shaft drive 4-3 backlash 0.05 – 0.32 mm (0.002 – 0.013 in) adjust backlash by selecting shims. (use two pieces of shims.) shim 1 size table part number thickness 24945-05a-0a0 0.30 mm (0.012 in) 24945-05a-0b0 0.35 mm (0.014 in) 24945-05a-0c0 0.40 mm (0.016 in) 24945-05a-0d0 0.50 mm (0.020 in) 24945-...

  • Page 115

    4-4 shaft drive removal secondary drive bevel gear the crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel ge...

  • Page 116

    Shaft drive 4-5 secondary driven bevel gear • remove the bearing stopper with the special tool. # 09921-21820: bearing retainer wrench inspection inspect the removed parts for the following abnormalities. * drive and driven bevel gears damage or wear * improper tooth contact * abnormal noise of bear...

  • Page 117

    4-6 shaft drive secondary gear shims adjustment backlash note: * hollow portion a of the secondary driven bevel gear assembly faces inside. * it is not necessary to apply suzuki bond “1207b” to the matching surface at this stage. • install the secondary drive bevel gear assembly with the re- moved s...

  • Page 118

    Shaft drive 4-7 • adjust the dial gauge so that it touches the secondary drive bevel gear cam dog; hold the driven bevel gear securely, and turn the drive bevel gear in each direction, reading the total backlash on the dial gauge. % secondary bevel gear backlash standard: 0.05 – 0.32 mm (0.002 – 0.0...

  • Page 119

    4-8 shaft drive 1 incorrect (contact at tooth top) 2 correct 3 incorrect (contact at tooth root) tooth contact after bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • remove the drive bevel gear assembly from ...

  • Page 120

    Shaft drive 4-9 reassembly secondary driven bevel gear • apply grease to the lip of oil seal. & 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the others) • tighten the bearing stopper to the specified torque with the special tool. ! Bearing stopper: 105 n.M...

  • Page 121: Final Bevel Gears

    4-10 shaft drive final bevel gears construction 1 oil seal 2 final gear bearing case 3 o-ring 4 plate 5 final driven gear bearing 6 shims (4 kinds) 7 final driven bevel gear 8 shims (8 kinds) 9 bearing retainer 0 final driven gear bearing a oil seal b final gear case c shims (5 kinds) d stopper plat...

  • Page 122

    Shaft drive 4-11 standard clearance a: 1.00 mm (0.039 in) shim 1 size table part number thickness 27445-38a00-030 0.30 mm (0.012 in) 27445-38a00-035 0.35 mm (0.014 in) 27445-38a00-040 0.40 mm (0.016 in) 27445-38a00-050 0.50 mm (0.020 in) 27445-38a00-060 0.60 mm (0.024 in) the shims 1 are available a...

  • Page 123

    4-12 shaft drive final gear case removal after draining final gear oil, the following components must be removed in the described order before removing the final gear case. Note: refer to the following pages for the details of each step. • drain final gear oil. ( "2-15) • remove the rear wheel. ( "7...

  • Page 124

    Shaft drive 4-13 1 spring 2 propeller shaft 3 circlip • using a chisel, unlock the nut. • remove the final drive bevel gear coupling nut with the special tool. # 09924-62430: 22 mm long socket 09924-64510: final drive gear coupling holder • remove the washer and the final drive coupling. • remove th...

  • Page 125

    4-14 shaft drive • remove the bearing from the final drive bevel gear with the bearing puller. $ the removed bearing must be replaced with a new one. Note: if no abnormal noise, the bearing removal is not necessary. • remove the final gear bearing case bolts. • remove the final gear bearing case fro...

  • Page 126

    Shaft drive 4-15 • remove the bearing retainer screws, using an impact driver set. # 09900-09004: impact driver set • remove the final driven gear bearing and oil seal with the spe- cial tools. # 09941-64511: bearing remover 09930-30102: sliding shaft $ the removed bearing and oil seal must be repla...

  • Page 127

    4-16 shaft drive • adjust the dial gauge so that it touches the backlash measur- ing tool arm at the mark; hold the final driven bevel gear se- curely, and turn the final drive bevel gear coupling slightly in each direction, reading the total backlash on the dial gauge. % final bevel gear backlash s...

  • Page 128

    Shaft drive 4-17 shims 1 specifications part no shim thickness 27326 34201 1.05 mm (0.041 in) 27326-34211 1.10 mm (0.043 in) 27326 34221 1.20 mm (0.047 in) 27326-34231 1.25 mm (0.049 in) 27326-34241 1.35 mm (0.053 in) 27326-34201-140 1.40 mm (0.055 in) 27326-34201-145 1.45 mm (0.057 in) 27326-34201-...

  • Page 129

    4-18 shaft drive tooth contact after backlash adjustment is carried out, the tooth contact must be checked. • remove the bolts from the final gear bearing case, and remove the case with the two 5 mm screws. ( "4-14) do not mis- place the shims. Remove the final driven bevel gear. • clean and de-grea...

  • Page 130

    Shaft drive 4-19 final gear case reassembly reassemble the final gear case in the reverse order of disassem- bly. Pay attention to the following points. • install a new oil seal 1 and o-ring 2 to the bearing stopper. $ use new o-ring and oil seat to prevent oil leakage. • install the bearing to the ...

  • Page 131

    4-20 shaft drive • install the needle roller bearing for the final driven bevel gear into the final gear case with the special tool. # 09913-76010: bearing installer note: the stamped ward on the bearing end should face to the driven bevel gear side. • install the bearing retainer. Apply a small qua...

  • Page 132

    Shaft drive 4-21 • apply suzuki bond “1207b” to the mating surface of the final gear case and final gear bearing case. $ do not block the breather passage when applying suzuki bond “1207b”. ( 99000-31140: suzuki bond “1207b” • apply thread lock “1342” to the final gear case bolts and tighten them to...

  • Page 133

    4-22 shaft drive • apply a small quantity of the thread lock “1303” to the final drive bevel gear coupling nut. ' 99000-32030: thread lock ‘‘1303’’ • tighten the nut to the specified torque with the special tool. ! Final drive bevel gear coupling nut: 100 n.M (10.0 kgf.M, 72.5 lb-ft) # 09924-62430: ...

  • Page 134

    Shaft drive 4-23 • install the stopper plate. $ when installing the plate, fit the protrusion a of plate to the one of the bearing stopper grooves. Note: two kinds of plates are available to lock the stopper at the proper position. Final gear case installation installation is in the reverse order of...

  • Page 135: Fuel and Lubrication System

    Fuel and lubrication system 5-1 fuel and lubrication system 5.

  • Page 136: Fuel System

    5-2 fuel and lubrication system fuel system the fuel pump is operated by a vacuum force which is supplied from the carburetor intake pipe. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. When the ne...

  • Page 137: Fuel Tank/fuel Valve

    Fuel and lubrication system 5-3 fuel tank/fuel valve removal ! Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • remove the front seat. ( "7-2) • remove the speedometer. • disconnect the speedometer coupler. # be careful not to scratch the fuel tank. • r...

  • Page 138

    5-4 fuel and lubrication system • remove the fuel valve. • disconnect the fuel hose 1 and vacuum hose 2. • remove the throttle stop screw. • remove the fuel tank. • remove the fuel level gauge mounting bolts. • remove the fuel level gauge 3. • remove the o-ring 4..

  • Page 139

    Fuel and lubrication system 5-5 fuel tank fuel valve 4.4 n.M (0.44 kgf.M, 3.2 lb-ft) cushion cushion cushion inspection fuel valve if the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check...

  • Page 140: Fuel Pump

    5-6 fuel and lubrication system 10 n.M (1 0 kgf m, 7.0 lb-ft) fuel tank fuel pump removal • remove the battery 1. • disconnect the lead wire coupler 2. • remove the ignitor 3. • disconnect the fuse case coupler 4. • remove the starter lead wire 5. • remove the battery case. • remove the fuel pump mo...

  • Page 141

    Fuel and lubrication system 5-7 inspection ! Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • disconnect the fuel hose 1, connect the suitable hose and insert the free end of the hose into a receptacle. Check the fuel flow when cranking the engine for f...

  • Page 142: Carburetor

    5-8 fuel and lubrication system carburetor construction a throttle stop screw b pilot screw c float d pilot jet e main jet holder f main jet g needle valve h coasting valve i throttle position sensor 1 top cap 2 spring 3 jet needle stopper 4 o-ring 5 e-ring 6 jet needle 7 diaphragm/piston valve 8 fu...

  • Page 143

    Fuel and lubrication system 5-9 specifications location of carburetor i d. No. The carburetor i.D. Is stamped on the location 1 on the carbure- tor as shown in the right pho o. Item specification e-02, 19, 24 e-03, 28 e-33 carburetor type mikuni bdsr34 ← ← bore size 34 mm ← ← i.D. No. 41f1 41f2 41f3...

  • Page 144

    5-10 fuel and lubrication system diaphragm and piston operation the carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the...

  • Page 145

    Fuel and lubrication system 5-11 air mixture fuel slow system this system supplies fuel to the engine during engine operation with throttle valve 1 closed or slight opened. The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through #1 ...

  • Page 146

    5-12 fuel and lubrication system main system as the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi a increases. This causes the piston valve 2 moves upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel passes around main air blee...

  • Page 147

    Fuel and lubrication system 5-13 air mixture fuel starter (enricher) system pulling the starter (enricher) plunger 1 causes fuel to be drawn into the starter circuit from the float chamber 2. The starter jet 3 meters this fuel. The fuel then flows into the fuel pipe 4 and mixes with the air coming f...

  • Page 148

    5-14 fuel and lubrication system fuel accelerator pump system this system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volum...

  • Page 149

    Fuel and lubrication system 5-15 removal • remove the fuel tank. ( "5-3) • loosen the air intake pipe clamp screws. • disconnect the breather hose. • move the air inlet pipe to forward. • remove the throttle cables 1. • disconnect the throttle position sensor coupler 2. • disconnect the air vent hos...

  • Page 150

    5-16 fuel and lubrication system • loosen the clamp screw and remove the carburetor. • remove the starter plunger. Disassembly • remove the carburetor top cap 1. • remove the spring 2 and piston valve 3 along with diaphragm 4. • pull out the jet needle holder 5..

  • Page 151

    Fuel and lubrication system 5-17 • remove the spring 1, washers 2, 3, retainer 4 and jet needle 5. • remove the float chamber 6. $ 09900-09004: impact driver set • remove the accelerator pump plunger 7. • remove the o-ring 8. # use a new o-ring to prevent fuel leakage. • remove the float 9 and needl...

  • Page 152

    5-18 fuel and lubrication system drill-stop pilot screw plug carburetor body • use a %” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. Thread a self-tapping s...

  • Page 153

    Fuel and lubrication system 5-19 • remove the casting valve cover. • remove the casting valve 1 and the spring 2..

  • Page 154

    5-20 fuel and lubrication system correct incorrect carburetor cleaning ! Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • clean all...

  • Page 155

    Fuel and lubrication system 5-21 carburetor heater inspection (for e02, e19) • disconnect the carburetor heater terminal lead wires. • connect the positive + terminal of a 12v battery to the termi- nal of the carburetor heater and the battery negative - termi- nal to the terminal. • check that the h...

  • Page 156

    5-22 fuel and lubrication system 45˚ float height adjustment • measure the float height a by using a calipers with the carbu- retor slanting at an angle of 45° (as shown in the right illustra- tion) and the float arm just contacting the needle valve. • bend the tongue b of the float arm as necessary...

  • Page 157

    Fuel and lubrication system 5-23 reassembly and reinstallation carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the follow- ing instructions. # * assemble the parts taking consideration of their func- tion. * replace o-rings and seals w...

  • Page 158

    5-24 fuel and lubrication system coasting valve • when installing the coasting valve to the body, align the hole a of the diagram and air hole b of the cover. Funnel • apply a small quantity of thread lock “1342” to the funnel stopper screws and tighten them. ( 99000-3250: thread lock “1342” pilot s...

  • Page 159

    Fuel and lubrication system 5-25 throttle position sensor positioning • install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle posi- tion sensor. • measure the resistance between the throttle position sensor terminals as shown in ...

  • Page 160: Lubrication System Chart

    5-26 fuel and lubrication system lubrication system chart pressure regulator oil pan oil pump driven chain driveshaft gears driveshaft driveshaft left bearing clutch plates clutch sleeve hub countershaft gears countershaft countershaft left bearing oil jet secondary bevel gear and bearings secondary...

  • Page 161

    Pair (air supply) system 5-27 p air pipe mar king t o air cleaner p air air cleaner hose p air v alv e hose p air co v er p air pipe p air v acuum hose p air v alv e pair (air supply) system hose routing.

  • Page 162

    5-28 pair (air supply) system pair (air supply) system inspection hoses • inspect the hoses for wear or damage. • inspect that the hoses and pipes are securely connected. Pair control valve • inspect that air flows through the pair control valve air inlet port to the air outlet ports. • if air does ...

  • Page 163: Cooling System

    Cooling system 6-1 contents cooling system 6.

  • Page 164: Engine Coolant

    6-2 cooling system gauge pressure (kgf/cm 2 ) engine coolant at the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will prot...

  • Page 165: Radiator And Water Hose

    Cooling system 6-3 radiator and water hose cooling circuit inspection before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • remove the fuel tank. ( #5-3) • remove the radiator cap 1 and connect the tester to the filler. " do not remove the radiato...

  • Page 166

    6-4 cooling system radiator removal • remove the fuel tank. ( #5-3) • remove the frame head covers 1. • disconnect the water hoses. • drain engine coolant. • remove the radiator cover 2. • remove the radiator mounting bolts. • remove the radiator..

  • Page 167

    Cooling system 6-5 radiator remounting the radiator is to be installed in the reverse order of the removal procedure. • install the radiator. • route the radiator hoses. ( #9-18) radiator cap inspection • fit the cap 1 to the radiator cap tester 2. • build up pressure slowly by operating the tester....

  • Page 168: Cooling Fan

    6-6 cooling system • the voltmeter is for making sure that the battery applies 12 volts to the motor. With the motor with electric motor fan run- ning at full speed, the ammeter should be indicating not more than 5 amperes. • if the fan motor does not turn, replace the motor assembly with a new one....

  • Page 169: Cooling Fan Thermo-Switch

    Cooling system 6-7 installation • put the cooling fan between the down tube and the engine. • tighten the down tube mounting bolts. ( #3-9) • tighten the cooling fan mounting bolts. • install the radiator. ( #6-5) cooling fan thermo-switch removal • remove the radiator. ( #6-4) • remove the cooling ...

  • Page 170: Engine Coolant Temperature

    6-8 cooling system oil installation • install the o-ring 1. • tighten the cooling fan thermo-switch to the specified torque. ' cooling fan thermo-switch: 17 n.M (1.7 kgf.M, 12.5 lb-ft) • install the radiator. Engine coolant temperature switch removal • remove the radiator. ( #6-4) • remove the engin...

  • Page 171: Thermostat

    Cooling system 6-9 inspection inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follow- ing manner. • pass a string between flange, as shown in the illustration. • immerse the thermostat in the water contained in a beaker, as shown in th...

  • Page 172: Water Pump

    6-10 cooling system valve lift • keep on heating the water to raise its temperature. • just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 6.0 mm (0.24 in). $ thermostat valve lift standard: over 6.0 mm at 90°c (over 0.24 in at 194°f) • a ther...

  • Page 173

    Cooling system 6-11 • remove the pin 1 and draw out the impeller shaft 2. • remove the mechanical seal ring 3 and rubber seal 4. • remove the bearing with the special tool. & 09921-20220: bearing remover set note: if no abnormal noise, bearing removal is not necessary. ! The removed bearing must be ...

  • Page 174

    6-12 cooling system inspection bearing • inspect the play of the bearing by hand while it is in the water pump case. • rotate the inner race by hand to inspect for abnormal noise and smooth rotation. • replace the bearing if there is anything unusual. Mechanical seal • visually inspect the mechanica...

  • Page 175

    Cooling system 6-13 • install the new mechanical seal with a suitable size socket wrench and the special tool. Note: the new mechanical seal has been applied the sealer a. & 09924-84521: bearing installer • install the new bearing with the special tool. & 09924-84521: bearing installer note: the sta...

  • Page 176

    6-14 cooling system • apply grease to the o-ring. • set the water pump shaft end a to the oil pump shaft b. ( 99000-25030: suzuki super grease “a” (for usa) 99000-25010: suzuki super grease “a” (for the others) • install the water pump screws. • apply engine coolant to the o-ring and install the wat...

  • Page 177: Chassis

    Chassis 7-1 contents chassis 7.

  • Page 178: Exterior Parts

    7-2 chassis exterior parts removal seat • remove the rear seat by removing the bolts. ! Be careful not to scratch the rear fender. • remove the rear seat grip band by removing the bolts. • remove the seat. ! Be careful not to scratch the rear fender. Frame cover • remove the left frame cover 1 with ...

  • Page 179

    Chassis 7-3 rear fender • remove the seat. ( "7-2) • disconnect the coupler 1. • remove the left or right side frame handle grip. • remove the rear fender 2. ! Be careful not to scratch the rear fenders. Note: when installing the frame handle grip bolts, apply a small quan- tity of thread lock “1303...

  • Page 180: Front Wheel

    7-4 chassis left right front wheel construction a front axle b axle pinch bolt c brake disc bolt $ item n.M kgf.M lb-ft a 65 6.5 47.0 b 33 3.3 24.0 c 23 2.3 16.5 1 front axle 2 bearing (r) 3 front wheel 4 spacer 5 bearing (l) 6 brake disc 7 spacer a front axle b brake disc mounting bolt $ item n.M k...

  • Page 181

    Chassis 7-5 removal and disassembly • loosen the front axle pinch bolt 1. • loosen the front axle 2 by using the special tool. % 09900-18710: hexagon socket (12 mm) • raise the front wheel off the ground with a jack or a wooden block. • remove the front axle 2, spacers 3 and front wheel. ! Do not op...

  • Page 182

    7-6 chassis inspection wheel bearings inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual. Wheel bearings removal...

  • Page 183

    Chassis 7-7 reassembly and remounting reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points: wheel bearing • apply suzuki super grease “a” to the bearings before in- stalling. For usa ' 99000-25030: suzuki super grease “...

  • Page 184

    7-8 chassis speed sensor • apply suzuki super grease “a” to the speed sensor dust seal. For usa ' 99000-25030: suzuki super grease “a” for the other countries ' 99000-25010: suzuki super grease “a” • align the grooves 1 on the speed sensor with the lugs 2 on the wheel hub. Front wheel • make sure th...

  • Page 185: Front Brake

    Chassis 7-9 front brake construction ) * the brake system is illed with an glycol-based brake fluid, which is classified dot 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake...

  • Page 186

    7-10 chassis brake pad replacement • remove the guide hook a. • remove the brake caliper by removing the brake caliper mount- ing bolts. • remove the pin 1. • remove the pad pin 2. • remove the brake pads 3. ! * do not operate the brake lever during or afte br ke pad removal. * replace the brake pad...

  • Page 187

    Chassis 7-11 brake fluid replacement • place the motorcycle on a level surface and keep the handlebar straight. • remove the master cylinder reservoir cap and diaphragm. • remove as much old brake fluid as possible. • fill the reservoir with new brake fluid. * specification and classification: dot 4...

  • Page 188

    7-12 chassis • remove the brake pads. ( "7-10) • remove the insulator. • remove the brake caliper holder. • remove the spring. • place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using compressed air. ! Do not use extremely high pressure to r...

  • Page 189

    Chassis 7-13 rubber parts replace the removed rubber parts with new ones. Brake caliper reassembly and remounting reassemble and remount the brake caliper in the reverse order of removal and disassembly. Pay special attention to the following points: • wash the caliper bores and pistons with the spe...

  • Page 190

    7-14 chassis • tighten the brake caliper mounting bolts 1, and brake hose union bolt 2 to the specified torque. $ brake caliper mounting bolt: 39 n.M (3.9 kgf.M, 28 lb-ft) brake hose union bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • for assembly procedure of brake hose: "9-18 • install the guide hook a. ...

  • Page 191

    Chassis 7-15 master cylinder removal and disassembly • place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. ! Immediately wipe off any brake fluid contacting any part of the motorcycl...

  • Page 192

    7-16 chassis • remove the piston assembly. Master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. Master cylinder reassembly and remounting reassemble and remount the master cy ind...

  • Page 193

    Chassis 7-17 • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • when remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper...

  • Page 194: Front Fork

    7-18 chassis front fork construction 1 o-ring 2 front fork spring 3 damper rod ring 4 rebound spring 5 damper rod 6 inner tube cover 7 rubber 8 washer 9 inner tube 0 slide metal a dust seal b oil seal stopper ring c oil seal d oil seal retainer e oil lock piece f inner tube cover guide g outer tube ...

  • Page 195

    Chassis 7-19 removal and disassembly • remove the front wheel. ( "7-5) • remove the brake hose from the hose guide. • remove the guide hook a. • remove the front brake caliper by removing the bolts. • remove the front fender by removing its mounting bolts. ! Be careful not to scratch the front fende...

  • Page 196

    7-20 chassis • remove the front fork inner tube cover 1, washer 2 and rub- ber 3. • remove the inner tube cover stopper 4 by loosening the bolt. • remove the inner tube cover guide 5. • remove the front fork spring stopper nut 6 and fork spring 7. % 09900-18720: hexagon socket (14 mm) • invert the f...

  • Page 197

    Chassis 7-21 • remove the dust seal 1 and the oil seal stopper ring 2. • remove the oil seal by slowly pulling out the inner tube. Note: be careful not to damage the inner tube. ! The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front...

  • Page 198

    7-22 chassis inspection inner and outer tubes inspect the inner tube sliding surface and outer tube sliding sur- face for scuffing. Fork spring measure the fork spring free length. If it is shorter than the ser- vice limit, replace it with a new one. & front fork spring free length service limit: 54...

  • Page 199

    Chassis 7-23 note: when installing the oil lock piece, insert the tapered end a of oil lock piece into the inner tube. • insert the inner tube into the outer tube and install the oil seal 1 using the special tool. % 09940-52861: front fork oil seal installer • install the oil seal stopper ring 2. ! ...

  • Page 200

    7-24 chassis fork oil • pour the specified fork oil into the inner tube. Fork oil type: suzuki fork oil ss-08 (#10) or equivalent fork oil , 99000-99001-ss8: suzuki fork oil ss-08 & front fork oil capacity (each leg): 412 ml (13.9/14.5 us/imp oz) • hold the front fork in a vertical position and adju...

  • Page 201

    Chassis 7-25 • install the inner tube cover 1, rubber 2 and washer 3. • remount the front fork and tighten the front fork lower clamp bolts temporarily. Note: install the inner tube a until it seets to the flange part b of the steering stem upper bracket. • tighten the front fork spring stopper nut ...

  • Page 202: Steering

    7-26 chassis steering construction removal and disassembly • remove the front wheel. ( "7-5) • remove the front fork. ( "7-19) • remove the rear view mirrors 1. 1 handlebars 2 handlebar balancer 3 handlebar set bolt cap 4 handlebar clamp/holder 5 steering stem upper bracket 6 steering stem nut 7 dus...

  • Page 203

    Chassis 7-27 • disconnect the front brake light switch lead wires 1. • remove the front brake master cylinder 2. • remove the right handlebar balancer 3, the right handlebar switch 4 and the throttle grip 5. • disconnect the clutch lever position switch lead wires 6. • loosen the clutch lever holder...

  • Page 204

    7-28 chassis • remove the steering stem head nut 1 and washer. • remove the steering stem upper bracket 2 and the front fork upper cover 3. Note: hold the front fork upper cover to prevent it from falling. • remove the cable guide 4. • remove the headlight. • remove the cooling air guide. • remove t...

  • Page 205

    Chassis 7-29 • remove the front turn signal light bracket. • disconnect the front turn signal light lead-wire connector. • remove the brake hose guide. • remove the brake hose and speedo sensor lead-wire. ( "9- 21) • remove the head light housing. • remove the head light housing bracket. • remove th...

  • Page 206

    7-30 chassis • remove the steering stem upper bearing 2. • remove the steering stem lower bearing 3. • remove the handlebar holders 4 from the steering stem up- per bracket. • remove the handlebar bushes by using the proper tool and special tools. % 09941-34513: steering outer race installer • remov...

  • Page 207

    Chassis 7-31 inspection and disassembly inspect the removed parts for the following abnormalities. * handlebars distortion * race wear and brinelling * bearing wear or damage * abnormal bearing noise * distortion of the steering stem • remove the steering stem lower bearing inner race by using a chi...

  • Page 208

    7-32 chassis • apply grease to the upper and lower bearings before remount- ing the steering stem. For usa # 99000-25030: suzuki super grease “a” for the other countries # 99000-25010: suzuki super grease “a” • install the bearings inner race and the dust seal. Steering stem nut • install the steeri...

  • Page 209

    Chassis 7-33 handlebar holder • install the handlebar holders and related parts to the steering stem head. • tighten the handlebar holder nuts to the specified torque. $ handlebar holder nut: 70 n.M (7.0 kgf.M, 50.5 lb-ft) steering stem upper bracket • install the front fork upper cover, steering st...

  • Page 210

    7-34 chassis forward punch mark clearance handlebars • when setting the handlebar clamp to the handlebar holder of the steering upper bracket, face the punched mark a on its clamp forward. • first, tighten the handlebar clamp bolts 1 to the half of speci- fied torque, and then tighten the handlebar ...

  • Page 211

    Chassis 7-35 • install the clutch lever holder with the punch mark a aligned with the clutch lever holder clamp as shown. $ clutch lever holder clamp bolt: 10 n.M (1.0 kgf.M, 7.3 lb-ft) • install the front wheel. ( '7-5) • adjust the throttle cable play. ( '2-10) steering tension adjustment check th...

  • Page 212: Rear Wheel

    7-36 chassis rear wheel construction 1 rear axle 2 spacer (lh) 3 lock washer 4 driven joint stopper 5 driven joint 6 damper 7 o-ring 8 bearing (lh) 9 spacer 0 bearing (rh) a wheel rim b brake shoe c brake camshaft d brake panel e brake cam lever a driven joint stopper bolt b rear axle nut c rear bra...

  • Page 213

    Chassis 7-37 left right for e-03, e-28, e-33 $ item n.M kgf.M lb-ft a 65 6.5 47 b 10 1.0 0.73 c 35 3.5 25.5 d 25 2.5 18.0 a rear axle nut b brake cam lever nut c rear torque link nut (f) d rear torque link nut (r).

  • Page 214

    7-38 chassis removal • remove the seat 1. ( '7-2) • remove the rear fender 2. ( '7-3) note: the rear fender removal is not necessary when the rear part of motorcycle can be lifted high enough to take the rear wheel out smoothly. • remove the exhaust pipes and mufflers assembly 3. ( '3-5) • remove th...

  • Page 215

    Chassis 7-39 • remove the rear swingarm left cover. • remove the rear axle shaft. Disassembly • flatten the lock washers. • remove the fitting bolts, washers and plates. • pull off the driven joint 1. • remove the o-ring 1. • remove the dampers with a screw driver. ! The removed o-ring must be repla...

  • Page 216

    7-40 chassis spacer left right left right clearance inspection and disassembly wheel bearing .................................................. '7-6 wheel axle ......................................................... '7-6 wheel rim ............................................................ '7-6 t...

  • Page 217

    Chassis 7-41 wheel damper • install the dampers. Note: if soap water is applied around the damper, it makes the job easier. Driven joint • install the driven joint. Note: apply grease to the o-ring and the final gear spline before install- ing the driven joint. For usa # 99000-25030: suzuki super gr...

  • Page 218: Rear Brake

    7-42 chassis rear brake removal and disassembly • remove the rear wheel. ( '7-38) • remove the rear brake panel. • remove the brake shoes. • remove the rear brake cam lever 1 and rear brake cam 2 by removing bolt. • remove the washer 3, o-ring 4 and spring 5..

  • Page 219

    Chassis 7-43 inspection brake drum inspect the brake drum and measure the brake drum i.D. To deter- mine the extent of wear. Replace the brake drum if the measure- ment exceeds the service limit. The value of this limit is indicated inside the brake drum. " 09900-20102: vernier calipers ( brake drum...

  • Page 220: Rear Brake Rod

    7-44 chassis • tighten the brake cam lever bolt to the specified torque. $ brake cam lever nut: 10 n.M (1.0 kgf.M, 7.0 lb-ft) • install the rear wheel. ( '7-41) • adjust the rear brake pedal free travel. ( '2-16) rear brake rod removal and disassembly • remove the exhaust pipes and mufflers assembly...

  • Page 221

    Chassis 7-45 • remove the rear brake adjust nut, spring and washer. • remove the rear brake link. • remove the cotter pins. Reassembly remounting reassemble and remount the rear brake rod in the reverse order of removal and disassembly. Pay attention to the fo low ng points. • apply grease to the re...

  • Page 222: Rear Suspension

    7-46 chassis rear suspension construction 1 rear shock absorber 2 rear cushion rod 3 spacer 4 rear cushion lever bearing 5 rear cushion lever 6 swingarm pivot bearing 7 swingarm bea ing 8 swingarm 9 b ot a rear shock absorber mounting nut b rear cushion rod mounting nut c rear cushion lever mounting...

  • Page 223

    Chassis 7-47 left right ( ) 50 n m 5.0 kgf m 36 0 lb-f ( ) 78 n.M 7.8 kgf.M 56.5 lb-ft ( ) 100 n.M 10.0 kgf.M 72 5 lb-ft ( ) 100 n.M 10.0 kgf.M 72.5 lb-ft 1 mm 1 mm 1 mm 1 mm ( ) 9.5 n.M 0.95 kgf.M 7.0 lb-ft.

  • Page 224

    7-48 chassis removal • remove the rear wheel. ( '7-41) • remove the final gear case with propeller shaft. • remove the secondary gear case cover 1. • remove the right frame lower cover 2, clutch rear cover 3. • remove the tool box. • remove the battery case. ( '5-6) : hooked part.

  • Page 225

    Chassis 7-49 • remove the cushion lever mounting bolt and nut. • remove the shock absorber upper mounting bolt and nut. • remove the right side swingarm pivot bolt lock nut 1. • remove the left and right side swingarm pivot bolts 2. Note: slightly loosen the cushion rod mounting nuts and the shock a...

  • Page 226

    7-50 chassis inspection and disassembly spacer • remove spacer from swingarm. • remove the spacers from the cushion lever. • inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. Swingarm bearing insert the spacer into swingarm cushion rod ...

  • Page 227

    Chassis 7-51 cushion lever bearing insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. • remove the cushion rod lower side bearing 1 by using the special tools. " 09921-20220: bearing remover set (17 mm)...

  • Page 228

    7-52 chassis reassembly reassemble the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the fol- lowing points: swingarm bearing • install the swingarm pivot bearing races by using the special tool. " 09913-70210: bearing installer set (40 mm) note: t...

  • Page 229

    Chassis 7-53 remounting remount the swingarm and shock absorber in the reverse order of disassembly and removal, and pay attention to the following points. Swingarm • before installing the swingarm, install the boot and the univer- sal joint. Note: make sure that the “up” mark a on the boot faces up...

  • Page 230

    7-54 chassis note: after tightening the swingarm pivot lock nut, be sure to check the swingarm operation. Shock absorber and cushion lever mounting nut • tighten the shock absorber upper mounting nut 1 to the speci- fied torque. $ shock absorber mounting nut: 50 n.M (5.0 kgf.M, 36.0 lb-ft) • tighten...

  • Page 231

    Chassis 7-55 note: to install the final gear case easily, move the dust boot front and the universal joint back. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven bevel gear shaft. • tighten the final gear case mounting nuts to the specified torque....

  • Page 233: Electrical System

    Electrical system 8-1 contents electrical system 8.

  • Page 234: Cautions In Servicing

    8-2 electrical system cautions in servicing connectors • when disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • when connecting a connector, push it in so it is firmly attached. • inspect the connector for corrosion, contamination and any breakage in the cover...

  • Page 235

    Electrical system 8-3 battery • the mf battery used in this motorcycle does not require main- tenance (e.G., electrolyte level inspection, distilled water re- plenishment). • during normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced...

  • Page 236

    8-4 electrical system location of electrical components 1 ignition switch 2 ignition coil #2 3 fuel level gauge 4 rear brake switch 5 cooling fan 6 cooling fan thermo-switch 7 speedometer sensor.

  • Page 237

    Electrical system 8-5 f oil pressure switch g generator h gear position switch i side-stand switch j fuse box k turn signal side-stand relay l regulator/rectifier 8 ignition coil #1 9 throttle position sensor 0 starter relay/main fuse a battery b ignitor c engine coolant temperature sensor d horn e ...

  • Page 238: Charging System

    8-6 electrical system charging system troubleshooting battery runs down quickly. Check accessories which use excessive accessories • remove accessories. Amounts of electricity. Are installed no accessories check the battery for current current leaks • short circuit of wire harness leaks. ( ! 8-7) • ...

  • Page 239

    Electrical system 8-7 measure the generator no-load voltage. ( ! 8-8) incorrect • faulty generator correct inspect the regulator/rectifier. Incorrect • faulty regulator/rectifier ( ! 8-9) correct inspect wirings. Incorrect • short circuit of wire harness poor contact of couplers correct • faulty bat...

  • Page 240

    8-8 electrical system y y y y y y generator coil resistance • remove the secondary gear case cover. • disconnect the generator coupler. Measure the resistance between the three lead wires. If the resistance is not specified value, replace the stator with a new one. Also, check that the generator cor...

  • Page 241

    Electrical system 8-9 regulator/rectifier • remove the secondary gear case cover. • disconnect the regulator/rectifier couplers. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified valve, replace the ...

  • Page 242: System

    8-10 electrical system starter motor starter relay to ignition coils and ignitor o/w clutch lever position switch starter button engine stop switch o/b turn signal/ side-stand re ay g ignition switch r fuse(30a) gear position witch fuse (15a) batter y bl side-stand switch b/w y/b b/y y/g starter sys...

  • Page 243

    Electrical system 8-11 check the starter relay. ( ! 8-13) incorrect • faulty starter relay correct • poor contact of the starter relay the starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up. Che...

  • Page 244

    8-12 electrical system commutator inspect the commutator for discoloration, abnormal wear or un- dercut a. If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth. If there is no under...

  • Page 245

    Electrical system 8-13 • apply a small quantity of suzuki moly paste to the arma- ture shaft. . 99000-25140: suzuki moly paste • align the tonque 1 on the brush holder with the groove 2 on the housing end. • align the threaded parts 3 on the housing end. • apply a small quantity of thread lock “1342...

  • Page 246

    8-14 electrical system ! When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the spe...

  • Page 247

    Electrical system 8-15 turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • remove the secondary gear case cover. • remove the turn signal/side-stand relay. Side-stand relay inspection first check the insulation bet...

  • Page 248: Ignition System

    8-16 electrical system generator pickup coil ignitor ignition coil #2 gnition coil #1 ignition switch main fuse battery fuse engine stop switch side stand relay throttle position sensor gear position switch g r y b/br bl r/b o/w g/bl b/w w b/y bl ¹ bl/w note: the ignition cut-off circuit is incorpor...

  • Page 249

    Electrical system 8-17 measure the battery voltage between input lead wires (o/w and b/w) at the ignitor with the ignition switch in the incorrect • faulty ignition switch “on” position. • faulty turn signal/side-stand relay • faulty engine stop switch correct • broken wire harness or poor connectio...

  • Page 250

    8-18 electrical system peak volt adaptor ignitor ig coil to engine stop switch inspection ignition coil primary peak voltage • remove the fuel tank. ( &5-3) • disconnect the two spark plug caps. • connect the new spark plugs to the each spark plug cap and ground them on the cylinder head. Note: make...

  • Page 251

    Electrical system 8-19 pickup coil peak voltage • remove the two seats. ( &7-2) • disconnect the wire harness coupler 1 at the ignitor. Note: make sure that all of the couplers are connected properly. Measure the pickup coil peak voltage in the following procedure. • connect the multi circuit tester...

  • Page 252

    8-20 electrical system pickup coil pickup coil coupler pickup coil peak volt adaptor pickup coil coupler g bl pickup coil pickup coil coupler ignitor coupler peak volt adaptor g bl/w • shift the transmission into the neutral, and then turn the igni- tion switch to the “on” position. • pull the clutc...

  • Page 253: Speedometer

    Electrical system 8-21 speedometer removal • remove the screws. • disconnect the cover and couple . ! When disconnecting and connecting the combination meter coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. • remove the speedometer..

  • Page 254

    8-22 electrical system parts names 1 high beam indicator light 2 engine coolant temperature indicator light 3 turn signal indicator light 4 oil pressure indicator light 5 neutral indicator light 6 fuel level meter 7 speedometer/tripmeter/clock 8 select button 9 adjust button operating procedure init...

  • Page 255

    Electrical system 8-23 0.5 second 3 seconds 3 seconds 3.5 seconds 3 seconds clock • displays the time (hours and minutes) on a 12-hour clock. • setting the time. Hold down the adjust button for two seconds while pressing the select button and then flashing the hour display. The setting that is flash...

  • Page 256

    8-24 electrical system to oil pressure switch inspection engine coolant temperature indicator light engine coolant temperature sensor inspection: &6-8 • remove the fuel tank. ( &5-3) • disconnect the engine coolant temperature sensor coupler. • connect the jumper wire to the wire harness coupler. Ch...

  • Page 257

    Electrical system 8-25 main wiring harness to fuel level gauge resistor fuel level meter • remove the fuel tank. ( &5-3) • connect the speedometer. • connect each resistor between the yellow/black and black/ white lead wire at the wire harness. • turn the ignition switch “on” position and wait for a...

  • Page 258

    8-26 electrical system (top) (bottom) fuel level gauge inspection • remove the fuel tank. ( &5-3) • remove the fuel level gauge. Measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. Float position resistance a “f...

  • Page 259

    Electrical system 8-27 v 10 k Ω 12 v b/w p o/r speed sensor speed sensor inspection if the speedometer, odometer or tripmeter does not function prop- erly. Inspect the speed sensor and connection of couplers. If the speed sensor and connection is all right, replace the unit with a new one. • remove ...

  • Page 260: Lamps

    8-28 electrical system lamps headlight, brake light/taillight and turn signal light ! If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. Headlight beam adjustment • adjust the headlight beam, both vertical ...

  • Page 261: Relays

    Electrical system 8-29 relays turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Inspection before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not...

  • Page 262

    8-30 electrical system inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Ignition switch (for e-24) r o o/y b/w on off lock color position (for others) r o o/y b/w gr br on off lock p color position lighting switch ...

  • Page 263: Battery

    Electrical system 8-31 battery specifications type designation ftx12-bs capacity 12v, 36 kc (10 ah)/10hr initial charging filling electrolyte • remove the aluminum tape 1 which seals the battery filler holes 2. • remove the caps 3 from the electrolyte container. Note: * do not remove or pierce the s...

  • Page 264

    8-32 electrical system correct incorrect note: if air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. • after the electroly...

  • Page 265

    Electrical system 8-33 recharging operation • measure the battery voltage using the multi circuit tester. If the voltage reading is less than the 12.0v (dc), recharge the bat- tery with a battery charger. ! * when recharging the battery, remove the battery from the motorcycle. * do not remove the ca...

  • Page 267: Servicing Information

    Servicing information 9-1 9 servicing information contents.

  • Page 268: Troubleshooting

    9-2 servicing information troubleshooting engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Worn cylinder. 2. Worn piston ring. 3. Worn valve guide or improper valve seating. 4. Loose spark plug. 5. Broken, cracked, or damaged pisto...

  • Page 269

    Servicing information 9-3 complaint symptom and possible causes remedy engine is noisy. Excessive valve chatter 1. Excessive valve clearance. 2. Weak or broken valve spring. 3. Worn camshaft. 4. Worn or burnt camshaft journal. Noise seems to come from the piston 1. Worn piston. 2. Worn cylinder. 3. ...

  • Page 270

    9-4 servicing information complaint symptom and possible causes remedy transmission jumps out of gear. 1. Worn gear. 2. Worn or distorted gearshift fork. 3. Weakened gearshift stopper spring. 4. Worn gearshift pawl. Replace. Replace. Replace. Replace. Engine idles poorly. 1. Valve clearance out of a...

  • Page 271

    Servicing information 9-5 complaint symptom and possible causes remedy engine overheats. 1. Carbon buildup on piston crown. 2. Insufficient amount of engine oil. 3. Defective oil pump. 4. Clogged oil circuit. 5. Float chamber fuel level too low. 6. Air leakage from intake pipe. 7. Incorrect engine o...

  • Page 272

    9-6 servicing information chassis steering is heavy. 1. Overtightened steering stem nut. 2. Broken bearing in steering stem. 3. Distorted steering stem. 4. Low tire pressure. Adjust. Replace. Replace. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. 2. Distorted fr...

  • Page 273

    Servicing information 9-7 brakes brake power insuffi- cient. 1. Leakage of brake fluid. 2. Worn brake pad/shoe. 3. Oil on brake pad surface. 4. Worn brake disc. 5. Air in hydraulic system. Repair or replace. Replace. Clean brake disc and brake pads. Replace. Bleed. Brake squeaks. 1. Carbon adhesion ...

  • Page 274

    9-8 servicing information electrical no sparking or poor sparking. 1. Defective ignition coil. 2. Defective spark plug. 3. Defective pick-up coil. 4. Defective ignitor unit. Replace. Replace. Replace. Replace. Spark plug is wet or quickly becomes fouled with carbon. 1. Excessively rich air/fuel mixt...

  • Page 275

    Servicing information 9-9 battery sulfation or spots on surfaces of cell plates. 1. Cracked battery case. 2. Battery has been left in a run-down condition for a long time. Replace. Replace. Battery runs down quickly. 1. Incorrect charging method. 2. Battery cell plates have lost much of their active...

  • Page 276: Wiring Diagram

    9-10 servicing information 1 on off on off push free off run off on on off • push free • l push r p lock off on • push hi lo + – b bl br dbr dg g gr lbl lg o p r w y b/bl b/br b/g b/r b/w b/y bl/b bl/w g/bl g/y o/b o/bl o/g o/r o/w o/y r/b r/w w/b y/b y/g y/w wire colors . . . . . . . . . . . . . . ...

  • Page 277

    Servicing information 9-11 for e-02, -19 1 on off on off push free off run off on on off • push • push free • l push r off s on p lock off on • push hi lo + – b bl br dbr dg g gr lbl lg o p r w y b/bl b/br b/g b/r b/w b/y bl/b bl/w g/bl g/y o/b o/bl o/g o/r o/w o/y r/b r/w w/b y/b y/g y/w wire color...

  • Page 278

    9-12 servicing information 1 on off on off push free off run off on on off • push free • l push r lock off on • push hi lo + – b bl br dbr dg g gr lbl lg o p r w y b/bl b/br b/g b/r b/w b/y bl/b bl/w g/bl g/y o/b o/bl o/g o/r o/w o/y r/b r/w w/b y/b y/g y/w wire colors . . . . . . . . . . . . . . . ...

  • Page 279

    Servicing information 9-13 after clamping, cut the excessive end. After clamping, cut the excessive end. 200 mm 50 mm 200 mm clamp handlebar switch (l & r) speed sensor clamp wiring harness front turn signal light (l & r) clamp clutch cable engine coolant temp. Switch starter motor lead wire c regul...

  • Page 280

    9-14 servicing information pass the battery + -lead wire under the starter relay. Clamp wiring harness thermo-switch view a battery - -lead wire view d sect b frame radiator wiring harness b a d to fuel level gauge carburetor h ater lead wire to spe dometer tps frame head cover (l & r) bend fuel pum...

  • Page 281

    Servicing information 9-15 a b oil pressure s witch 14 n . M 1.4 kgf . M lb-ft ( ) view b view a star ter motor star ter motor lead wire batter y - lead wire 80 – 100˚ 45˚ – 25˚ cr ankcase (r) clamp clamp gener ater lead wire 30˚ – 60˚ gear position s witch lead wire gener ator co v er star tor clam...

  • Page 282

    9-16 servicing information cable routing ch bl guide wiring harness wiring harness clutch cable clutch cable cabl throttle cable (pulling) e g throttle cable (pulling) throttle cable (pulling) thrott e cab e (pulling) throttle cable plate throttle cable plate reservoir hose reservoir hose l clamp cl...

  • Page 283

    Servicing information 9-17 fuel hose routing a view a 11.5 mm 10 mm b – b b b fuel v alv e fuel hose clamp clamp clamp clamp spr ing fuel hose t o fuel v alv e t o fuel pump f ace the clamp ends do wn. F ace the clamp ends do wn..

  • Page 284

    9-18 servicing information clutch cab le p ass through the v acuum hose left side of the breather hose . Air v ent hose wir ing har ness radiator cap f ace the clamp ends do wnw ard. Throttle cab les mar king clamp from top . Wir ing har ness v acuum hose fuel hose reser v oir hose reser v oir inlet...

  • Page 285

    Servicing information 9-19 front brake hose routing f ront br ak e master cylinder gask et w asher 42 ˚ set the br ak e hose union par allel with the handlebars , tighten the union bolt to the specified torque . P ass the br ak e hose through the hose guides . Speed sensor lead wire inser t the proj...

  • Page 286

    9-20 servicing information battery protector battery protector battery protector 60 mm 0 m 0 0 mm 30 mm 90 mm 90 mm 30 mm 65 mm 30 mm speed sensor lead wire clamp speed sensor guide hook speed sensor lead wire speed sensor lead wire routing.

  • Page 287: Special Tools

    Servicing information 9-21 special tools 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-20102 vernier calipers (200 mm) 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (50 – 75 mm) 09900-20205 micrometer (0 – 25 mm) 09900-20508 cylinder gauge set 09900-20602 dial gauge (1...

  • Page 288

    9-22 servicing information 09924-84521 bearing installer 09930-10121 spark plug wrench set 09930-11920 torx bit jt40h 09930-33730 rotor remover 09930-40113 rotor holder 09916-84511 tweezers 09916-14510 valve lifter 09916-14910 valve lifter attachment 09916-22430 valve seat cutter (n-128) 09916-34550...

  • Page 289

    Servicing information 9-23 09941-34513 steering outer race installer 09941-50111 bearing remover set 09941-54911 bearing outer race remover 09940-52861 front fork oil seal installer 09941-74911 steering bearing installer 09943-74111 front fork oil level gauge 09940-92720 spring scale 09941- 4511 bea...

  • Page 290: Tightening Torque

    9-24 servicing information tightening torque engine item n.M kgf.M lb-ft rocker arm shaft 27 2.7 19.5 cylinder head cover bolt 6 mm 10 1.0 7.0 8 mm 25 2.5 18.0 cylinder head bolt and nut 8 mm initial 10 1.0 7.0 final 25 2.5 18.0 10 mm initial 25 2.5 18.0 final 38 3.8 27.5 cam sprocket bolt 15 1.5 11...

  • Page 291

    Servicing information 9-25 item n.M kgf.M lb-ft oil plug 6 mm 6 0.6 4.3 8 mm 18 1.8 13.0 10 mm 15 1.5 11.0 14 mm 23 2.3 16.5 16 mm 35 3.5 25.5 engine mounting bolt 79 7.9 57.0 engine mounting bracket bolt 23 2.3 16.5 frame mounting bolt/nut 8 mm 23 2.3 16.5 10 mm 50 5.0 36.0 exhaust pipe clamp bolt ...

  • Page 292

    9-26 servicing information chassis item n.M kgf.M lb-ft front axle 65 6.5 47.0 front axle pinch bolt 33 3.3 24.0 brake disc bolt 23 2.3 16.5 front fork cap bolt 45 4.5 33.1 front fork spring stopper nut 35 3.5 25.5 front fork damper rod bolt 20 2.0 14.5 front fork lower clamp bolt 33 3.3 24.0 steeri...

  • Page 293

    Servicing information 9-27 tightening torque chart for other bolts and nuts listed previously, refer to this chart: bolt diameter conventional or “4” marked bolt “7” marked bolt a (mm) n.M kgf.M lb-ft n.M kgf.M lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 1.0 7.0 8 13...

  • Page 294: Service Data

    9-28 servicing information valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) ——— ex. 26 (1.02) ——— valve clearance in. 0.08 – 0.13 (when cold) (0.003 – 0.005) ——— ex. 0.17 – 0.22 (0.007 – 0.009) ——— valve guide to valve stem in. 0.010 – 0.037 clearance (0.0004 – 0.0015) ——— e...

  • Page 295

    Servicing information 9-29 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.95 – 35.99 35.65 front (1.415 – 1.417) (1.404) ex. 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) in. 35.50 – 35.54 35.20 rear (1.398 – 1.399) (1.386) ex. 36.58 – 36.62 36.28 (1.440 – 1.442) (1.428) ...

  • Page 296

    9-30 servicing information item standard limit piston ring free end gap 1st approx. 9.6 7.7 (0.38) (0.30) 2nd r approx. 11.8 9.4 (0.46) (0.37) piston ring end gap 1st 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 2nd 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) piston ring groove clearance 1st ——— 0.180 (0.0...

  • Page 297

    Servicing information 9-31 oil pump item standard limit oil pressure (at 60°c,140°f) above 350 kpa (3.5 kgf/cm 2 , 50 psi) below 650 kpa (6.5 kgf/cm 2 , 92 psi) ——— at 3 000 r/min. Clutch unit: mm (in) item standard limit clutch cable play 10 – 15 (0.4 – 0.6) ——— clutch release screw 1/4 turn back d...

  • Page 298

    9-32 servicing information shaft drive unit: mm (in) item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) ——— final bevel gear backlash drive side 0.03 – 0.064 (0.001 – 0.025) ——— damper spring free length 58.5 ——— (2.30) carburetor item specification e-02, 19, 24 e-03, 28 e...

  • Page 299

    Servicing information 9-33 electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: dpr7ea-9 denso: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 2 – 6 Ω terminal – terminal secondary 15 – 30 k Ω plug c...

  • Page 300

    9-34 servicing information suspension unit: mm (in) item standard/specification limit front fork stroke 140 (5.51) ——— front fork spring free length 551.7 540.6 (21.73) (21.29) front fork oil level (without spring) 177 (6.96) ——— front fork oil type suzuki fork oil ss-08 or an equivalent fork oil ——...

  • Page 301

    Servicing information 9-35 r + m 2 use only unleaded gasoline of at least 87 pump octane or 91 octane ( ) or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhib ...

  • Page 303

    Emission control information 10-1 contents emission control information 10

  • Page 304: 1 2 3 4 5 6 7 8 9 0

    10-2 emission contorol information 1 2 3 4 5 6 7 8 9 0 emission control carburetor components vl800 motorcycles are equipped with precision, manufactured carburetors for emission level control. These caburetors require special mixture control components and other precision adjustments to function pr...

  • Page 305: (California Model Only)

    Emission control information 10-3 evaporative emission control system (california model only) fuel tank carburetor surge control valve fuel valve canister fuel pump ptc valve intake pipe pair valve carburetors.

  • Page 306

    10-4 emission contorol information 13590-41f00 valve comp, air vent 09401-09403 clip, air vent valve hose 09404-06431 clamp, air vent hose air vent hose 09355-40805 480 hose, air vent valve vac air vent hose 13595-41f00 hose, air vent valve 15801-19f00 hose,air vent 13590-41f00 valve comp, air vent ...

  • Page 307

    Emission control information 10-5 carburetor surge control valve • remove the carbretor surge control valve. • connect the vacuum pump to the vacuum port as shown. • apply the specified negative pressure to the carburetor surge control valve. • the specified negative pressure must be maintained. • r...

  • Page 308

    10-6 emission contorol information blocked tube b • plug the canister port b. • air should not flow through the carburetor surge control valve and out the open air port. • replace the carburetor surge control valve if air leaks out the open air port. Air b a • remove the vacuum pump and blow air thr...

  • Page 309: Vl800K2 (’02-Model)

    Vl800k2 (’02-model) 11-1 contents vl800k2 (’02-model) 11 specifications ..............................................................................11- 2 service data .................................................................................11- 4.

  • Page 310: Specifications

    11-2 vl800k2 (’02-model) specifications dimensions and dry mass overall length ................................................................ 2 510 mm (98.818 in) overall width ................................................................. 985 mm (38.779 in) overall height ........................

  • Page 311

    Vl800k2 (’02-model) 11-3 chassis front suspension .......................................................... Telescopic, coil spring, oil damped rear suspension ........................................................... Link type, coil spring, oil damped, spring pre-load 7-way adjustable steering a...

  • Page 312: Service Data

    11-4 vl800k2 (’02-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) ——— ex. 26 (1.02) ——— valve clearance in. 0.08 – 0.13 (when cold) (0.003 – 0.005) ——— ex. 0.17 – 0.22 (0.007 – 0.009) ——— valve guide to valve stem in. 0.010 – 0.037 clearance (0.0004 – 0....

  • Page 313

    Vl800k2 (’02-model) 11-5 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 35.95 – 35.99 35.65 front (1.415 – 1.417) (1.404) ex. 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) in. 35.50 – 35.54 35.20 rear (1.398 – 1.399) (1.386) ex. 36.58 – 36.62 36.28 (1.440 – 1.442) (1.428) ca...

  • Page 314

    11-6 vl800k2 (’02-model) item standard limit piston ring free end gap 1st approx. 9.6 7.7 (0.38) (0.30) 2nd r approx. 11.8 9.4 (0.46) (0.37) piston ring end gap 1st 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 2nd 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) piston ring groove clearance 1st ——— 0.180 (0.007...

  • Page 315

    Vl800k2 (’02-model) 11-7 oil pump item standard limit oil pressure (at 60°c,140°f) above 350 kpa (3.5 kgf/cm 2 , 50 psi) below 650 kpa (6.5 kgf/cm 2 , 92 psi) ——— at 3 000 r/min. Clutch unit: mm (in) item standard limit clutch cable play 10 – 15 (0.4 – 0.6) ——— clutch release screw 1/4 turn back dri...

  • Page 316

    11-8 vl800k2 (’02-model) shaft drive unit: mm (in) item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) ——— final bevel gear backlash drive side 0.03 – 0.064 (0.001 – 0.025) ——— damper spring free length 58.5 ——— (2.30) carburetor item specification e-02, 19, 24 e-03, 28 e-3...

  • Page 317

    Vl800k2 (’02-model) 11-9 electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: dpr7ea-9 denso: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 2 – 6 Ω terminal – terminal secondary 15 – 30 k Ω plug cap...

  • Page 318

    11-10 vl800k2 (’02-model) suspension unit: mm (in) item standard/specification limit front fork stroke 140 (5.51) ——— front fork spring free length 551.7 540.6 (21.73) (21.29) front fork oil level (without spring) 177 (6.96) ——— front fork oil type suzuki fork oil ss-08 or an equivalent fork oil ———...

  • Page 319

    Vl800k2 (’02-model) 11-11 r + m 2 use only unleaded gasoline of at least 87 pump octane or 91 octane ( ) or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibi ...

  • Page 321: Vl800K3 (’03-Model)

    Vl800k3 (’03-model) 12- 1 contents vl800k3 (’03-model) 12 this chapter describes service data, service specifications and servicing procedures which dif- fer from those of the vl800k2 (’02-model). Note: * please refer to the chapter 1 through 11 for details which are not given in this chapter. Speci...

  • Page 322: Specifications

    12-2 vl800k3 (’03-model) specifications dimensions and dry mass overall length....................................................... 2 510 mm (98.8 in) overall width ........................................................ 985 mm (38.7 in) overall height................................................

  • Page 323

    Vl800k3 (’03-model) 12-3 chassis front suspension................................................. Telescopic, coil spring, oil damped rear suspension ................................................. Link type, coil spring, oil damped, spring pre-load 7-way adjustable steering angle ..................

  • Page 324: Service Data

    12-4 vl800k3 (’03-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) ...

  • Page 325

    Vl800k3 (’03-model) 12-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. ...

  • Page 326

    12-6 vl800k3 (’03-model) conrod + crankshaft unit: mm (in) item standard limit piston ring free end gap 1st approx. 9.6 (0.38) 7.7 (0.30) 2nd r approx. 11.8 (0.46) 9.4 (0.37) piston ring end gap 1st 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) 2nd 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) piston ring gro...

  • Page 327

    Vl800k3 (’03-model) 12-7 oil pump clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit oil pressure (at 60°c,140°f) above 350 kpa (3.5 kgf/cm 2 , 50 psi) below 650 kpa (6.5 kgf/cm 2 , 92 psi) at 3 000 r/min. — item standard limit clutch cable play 10 – 15 (0.4 – 0.6) — cl...

  • Page 328

    12-8 vl800k3 (’03-model) shaft drive unit: mm (in) carburetor thermostat + radiator + fan + engine coolant item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.064 (0.001 – 0.025) — damper spring free length — 58.5 (2.30) item ...

  • Page 329

    Vl800k3 (’03-model) 12-9 electrical unit: mm (in) item specification note firing order 1·2 spark plug type ngk: dpr7ea-9 denso: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 2 – 6 Ω terminal – terminal secondary 15 – 30 k Ω plug cap...

  • Page 330

    12-10 vl800k3 (’03-model) wattage unit: w suspension unit: mm (in) item specification e-03, 28, 33 e-24 the others headlight hi 60 ← ← lo 55 ← ← position/parking light 4 brake light/taillight 21/5 ← ← turn signal light 21/5 (front), 21 (rear) 21 ← speedometer light led ← ← water temp. Meter light le...

  • Page 331

    Vl800k3 (’03-model) 12-11 brake + wheel unit: mm (in) tire unit: mm (in) item standard limit rear brake pedal free travel 20 – 30 (0.8 – 1.2) — rear brake pedal height 75 – 85 (3.0 – 3.3) — brake drum i.D. Rear — 180.7 (7.11) brake disc thickness front 5.0 ± 0.2 (0.20 ± 0.01) 4.5 (0.18) brake disc r...

  • Page 332

    12-12 vl800k3 (’03-model) fuel + oil + coolant item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane ( ) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with...

  • Page 333: Wiring Diagram

    Vl800k3 (’03-model) 12-13 wiring diagram for e-02, 19 1 on off on off push free off run off on on off • push • push free • l push r off on p lock off on • push hi lo + – b bl br dbr dg g gr lbl lg o p r w y b/bl b/br b/g b/r b/w b/y bl/b bl/w g/bl g/y g/w o/b o/bl o/g o/r o/w o/y r/b r/bl r/w w/b w/...

  • Page 334

    12-14 vl800k3 (’03-model) for e-03, 28, 33 1 on off on off push free off run off on on off • push free • l push r p lock off on • push hi lo + – tu hi oi wt nu 2 3 4 6 5 1 + – on off m 12 v diode rear turn signal light (l) b/w b/w tu : turn signal indica tor light hi : high beam indica tor light nu ...

  • Page 335

    Vl800k3 (’03-model) 12-15 for e-24 1 on off on off push free off run off on on off • push free • l push r lock off on • push hi lo + – tu hi oi wt nu 2 3 4 6 5 1 + – on off m 12 v b bl br dbr dg g gr lbl lg o p r w y b/bl b/br b/g b/r b/w b/y bl/b bl/w g/bl g/y g/w o/b o/bl o/g o/r o/w o/y r/b r/bl ...

  • Page 337: Vl800K4 (’04-Model)

    Vl800k4 (’04-model) 13- 1 contents vl800k4 (’04-model) 13 this chapter describes servicing procedures which differ from those of the vl800k3 (’03-model). Note: * please refer to the chapters 1 through 12 for details which are not given in his chapter. Specifications ....................................

  • Page 338: Specifications

    13-2 vl800k4 (’04-model) specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width ....................................................................................... 985 mm (38.8 ...

  • Page 339: Service Data

    Vl800k4 (’04-model) 13-3 service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) ...

  • Page 340

    13-4 vl800k4 (’04-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. ...

  • Page 341

    Vl800k4 (’04-model) 13-5 conrod + crankshaft unit: mm (in) item standard limit piston ring free end gap 1st approx. 9.6 (0.38) 7.7 (0.30) 2nd r approx. 11.8 (0.46) 9.4 (0.37) piston ring end gap 1st 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) 2nd 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) piston ring gro...

  • Page 342

    13-6 vl800k4 (’04-model) oil pump clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit oil pressure (at 60°c,140°f) above 350 kpa (3.5 kgf/cm 2 , 50 psi) below 650 kpa (6.5 kgf/cm 2 , 92 psi) at 3 000 r/min — item standard limit clutch cable play 10 – 15 (0.4 – 0.6) — clu...

  • Page 343

    Vl800k4 (’04-model) 13-7 shaft drive unit: mm (in) carburetor thermostat + radiator + fan + engine coolant item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.064 (0.001 – 0.025) — damper spring free length — 58.5 (2.30) item ...

  • Page 344

    13-8 vl800k4 (’04-model) electrical unit: mm (in) wattage unit: w item specification note firing order 1·2 spark plug type ngk: dpr7ea-9 denso: x22epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 2 – 6 Ω terminal – terminal secondary 15 –...

  • Page 345

    Vl800k4 (’04-model) 13-9 suspension unit: mm (in) brake + wheel unit: mm (in) item standard/specification limit front fork stroke 140 (5.51) — front fork spring free length 551.7 (21.73) 540.6 (21.29) front fork oil level (without spring) 177 (6.96) — front fork oil type suzuki fork oil ss-08 or an ...

  • Page 346

    13-10 vl800k4 (’04-model) tire unit: mm (in) fuel + oil + coolant item standard/specification limit cold inflation tire pressure (solo riding) front 200 kpa (2.00 kgf/cm 2 , 29 psi) — rear 250 kpa (2.50 kgf/cm 2 , 36 psi) — cold inflation tire pressure (dual riding) front 200 kpa (2.00 kgf/cm 2 , 29...

  • Page 347: Periodic Maintenance Chart

    Vl800k4 (’04-model) 13-11 periodic maintenance chart i = inspect and adjust, clean, lubricate or replace lubricate as necessary. R= replace t= tighten interval item km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 15 000 months 2 12 24 36 48 air cleaner element — i i r i spark plugs ...

  • Page 348: Cooling Hose Routing

    13-12 vl800k4 (’04-model) cooling hose routing clutch cable p ass through the v acuum hose left side of the breather hose . Air v ent hose wir ing har ness radiator cap f ace the clamp ends do wnw ard. Throttle cab les mar king clamp from top . Wir ing har ness v acuum hose fuel hose reser v oir hos...

  • Page 349

    Vl800k4 (’04-model) 13-13 rear combination light installation rear fende clamp inside of the rear fender clamp.

  • Page 350: Warning Diagram

    13-14 vl800k4 (’04-model) warning diagram for e-03, 28, 33 on off off run off on on off push push free l push r off on p lock off on push hi lo on off + – 1 push free on off m 12 v 2 3 4 6 5 1 + – hi wt nu tu oi rear turn signal light (l) tu : turn signal indica t or light hi : high beam indica t or...

  • Page 351

    Vl800k4 (’04-model) 13-15 for e-24 on off off run off on on off push push free l push r off on p lock off on push hi lo on off + – 1 push free on off m 12 v 2 3 4 6 5 1 + – hi t u tu rear turn signal light (l) tu : turn signal indica t or light hi : high beam indica t or light nu : neutral indica t ...

  • Page 353: Vl800K5 (’05-Model)

    Vl800k5 (’05-model) 14- 1 contents vl800k5 (’05-model) 14 country and area codes the following codes stand for the applicable country (-ies) and area (-s). Code country or area effective frame no. 000 e-02 e-19 e-24 e-03 e-28 e-33 japan u.K. Eu australia u.S.A. (except for california) canada califor...

  • Page 354: Specifications

    14-2 vl800k5 (’05-model) specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width ....................................................................................... 985 mm (38.8 ...

  • Page 355: Manual

    Vl800k5 (’05-model) 14-3 abbreviations used in this manual a abdc : after bottom dead center ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center atm pressure: atmospheric pressure : atmospheric pressure sensor (aps, ap sensor) a...

  • Page 356

    14-4 vl800k5 (’05-model) m mal-code : malfunction code (diagnostic code) max : maximum mil : malfunction indicator lamp (led) min : minimum n nox : nitrogen oxides o ohc : over head camshaft ops : oil pressure switch p pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom :...

  • Page 357: Sae-to-Former Suzuki Term

    Vl800k5 (’05-model) 14-5 sae-to-former suzuki term this table lists sae (society of automotive engineers) j1930 terms and abbreviations which may be used in this manual in compliance with sae recommendations, as well as their former suzuki names. Sae term former suzuki term full term abbreviation a ...

  • Page 358

    14-6 vl800k5 (’05-model) sae term former suzuki term full term abbreviation i idle speed control ignition control ignition control module intake air temperature m malfunction indicator lamp manifold absolute pressure mass air flow o on-board diagnostic open loop p programmable read only memory pulse...

  • Page 359: Service Data

    Vl800k5 (’05-model) 14-7 service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) ---- ex. 26 (1.02) ---- valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) ---- ex. 0.17 – 0.22 (0.007 – 0.009) ---- valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 ...

  • Page 360

    14-8 vl800k5 (’05-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. ...

  • Page 361

    Vl800k5 (’05-model) 14-9 conrod + crankshaft unit: mm (in) piston ring free end gap 1st approx. 9.6 (0.38) 7.7 (0.30) 2nd r approx. 11.8 (0.46) 9.4 (0.37) piston ring end gap 1st 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) 2nd 0.20 – 0.35 (0.008 – 0.014) 0.70 (0.028) piston ring to groove clearance 1st...

  • Page 362

    14-10 vl800k5 (’05-model) oil pump clutch unit: mm (in) transmission unit: mm (in) except ratio crankshaft thrust bearing thickness 1.925 – 2.175 (0.0758 – 0.0856) ---- crankshaft thrust clearance 0.05 – 0.10 (0.002 – 0.004) ---- crankshaft runout ---- 0.05 (0.002) item standard limit oil pressure (...

  • Page 363

    Vl800k5 (’05-model) 14-11 shaft drive unit: mm (in) thermostat + radiator + fan + engine coolant shift fork groove width no.1 5.50 – 5.60 (0.217 – 0.220) ---- no.2 4.50 – 4.60 (0.177 – 0.181) ---- shift fork thickness no.1 5.30 – 5.40 (0.209 – 0.213) ---- no.2 4.30 – 4.40 (0.169 – 0 173) ---- item s...

  • Page 364

    14-12 vl800k5 (’05-model) * injector + fuel pump + fuel pressure regulator * fi sensors+ secondary throttle valve actuator item specification note * injector resistance 11 – 13 Ω at 20 °c (68 °f) * fuel pump discharge amount approx. 168 ml (5.7/5.9 us/lmp oz) and more/10 sec. * fuel pressure regulat...

  • Page 365

    Vl800k5 (’05-model) 14-13 * throttle body electrical unit: mm (in) item specification bore size * 34 mm i.D. No. * 41f1 (for e-33), 41f0 (for the others) idle r/min. * 1 100 ± 100 r/min. Fast idle r/min. * 2 100 r/min. (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specifi...

  • Page 366

    14-14 vl800k5 (’05-model) wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 w ← ← lo 55 w ← ← position/parking light 4 w brake light/taillight 21/5 w ← ← turn signal light 21/5 w (front), 21 w (rear) 21 w ← speedometer light led ← ← engine coolan...

  • Page 367

    Vl800k5 (’05-model) 14-15 tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front 200 kpa (2.00 kgf/cm², 29 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 200 kpa (2.00 kgf/cm², 29 psi) ---- rear 250 kpa ...

  • Page 368

    14-16 vl800k5 (’05-model) fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10 % ethanol, or less than 5 % methanol with...

  • Page 369: Periodic Maintenance Chart

    Vl800k5 (’05-model) 14-17 periodic maintenance chart note: i=inspect and clean, adjust, replace or lubricate as necessary; r=replace; t=tighten engine idle speed note: warm up the engine before adjusting the engine idle speed. • start the engine, turn the throttle stop screw 1 and set the engine idl...

  • Page 370: Precautions In Servicing

    14-18 vl800k5 (’05-model) precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a lock typ...

  • Page 371

    Vl800k5 (’05-model) 14-19 • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of fema...

  • Page 372

    14-20 vl800k5 (’05-model) • when disconnecting and connecting the ecm, make sure to turn off the ignition switch 1, or electronic parts may get damaged. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly when...

  • Page 373

    Vl800k5 (’05-model) 14-21 electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are ...

  • Page 374

    14-22 vl800k5 (’05-model) continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. 1 ecm • disconnect the coupler b and measure resistance between couplers a and b. I...

  • Page 375

    Vl800k5 (’05-model) 14-23 short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/coup...

  • Page 376

    14-24 vl800k5 (’05-model) using the multi-circuit tester • use the suzuki multi-circuit tester set (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of...

  • Page 377

    Vl800k5 (’05-model) 14-25 fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. The...

  • Page 378

    14-26 vl800k5 (’05-model) compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine coolant temperature sen- sor signal when engine coolant temp...

  • Page 379

    Vl800k5 (’05-model) 14-27 fi system parts location a iap sensor (rear cylinder) f pair control solenoid valve b ignition coil no.1 (rear cylinder) g ckp sensor c ect sensor h gp switch d fuel injector (rear cylinder) i fp relay e fuel injector (front cylinder) ecm a b c d e f g h i.

  • Page 380

    14-28 vl800k5 (’05-model) j ho2 sensor n stp sensor k to sensor o tp sensor l stva p iap sensor (front cylinder) m speedometer q ignition coil no.2 (front cylinder) j k l n o q p m ecm.

  • Page 381

    Vl800k5 (’05-model) 14-29 fi system wiring diagram intak e air pressure sensor (iaps) f ront intak e air pressure sensor (iaps) rear engine coolant temper ature sensor (ects) intak e air temper ature sensor (ia ts) tip-o v er sensor (t os) t o fuel pump rela y ecm heated o xygen sensor (ho2s) fuel p...

  • Page 382: Self-Diagnosis Function

    14-30 vl800k5 (’05-model) self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi light). To check the function of the individual fi system devices,...

  • Page 383

    Vl800k5 (’05-model) 14-31 dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive signal from the devices...

  • Page 384

    14-32 vl800k5 (’05-model) in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The malfunction code is indicated in three digits. ...

  • Page 385

    Vl800k5 (’05-model) 14-33 tps adjustment 1. Lift and support the fuel tank. ( $14-93) 2. Adjust the engine rpm to 1 100 rpm. Note: warm up the engine before adjustment. 3. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. 4. If the throttle position sens...

  • Page 386: Fail-Safe Function

    14-34 vl800k5 (’05-model) fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from each...

  • Page 387: Fi System Troubleshooting

    Vl800k5 (’05-model) 14-35 fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper an...

  • Page 388

    14-36 vl800k5 (’05-model) note: the above form is a standard sample. The form should be modified according to condition and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual ...

  • Page 389

    Vl800k5 (’05-model) 14-37 self-diagnostic procedures note: * don’t disconnect couplers from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in the memory. Such disconnection wil...

  • Page 390

    14-38 vl800k5 (’05-model) self-diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • if the malfunction code indicates (c00), the malfunction is cleared. • disconnect the special tool from the dealer mode coupler. Note: * even though the malfuncti...

  • Page 391

    Vl800k5 (’05-model) 14-39 use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase t...

  • Page 392

    14-40 vl800k5 (’05-model) show data when trouble (displaying data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it i...

  • Page 393

    Vl800k5 (’05-model) 14-41 • click “show data when trouble” 1 to display the data. By clicking the drop down button 2, either “failure #1” or “failure #2” can be selected..

  • Page 394: Ecm Terminal

    14-42 vl800k5 (’05-model) ecm terminal terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) h ignition switch signal (at) 2 iat sensor signal (iat) i ect sensor signal (ect) 3 rear cylinder iap sensor signal (iap. R) j to sensor signal (tos) 4 stp sensor signal (stp) k tp sensor signal ...

  • Page 395

    Vl800k5 (’05-model) 14-43 malfunction code and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical p...

  • Page 396

    14-44 vl800k5 (’05-model) dtc no. Detected item detected failure condition check for c21 iat sensor the sensor voltage should be the fol- lowing. 0.1 v sensor voltage in other than the above range, c21 (p0110) is indicated. Iat sensor, lead wire/coupler connection. P0110 h sensor voltage is higher t...

  • Page 397

    Vl800k5 (’05-model) 14-45 dtc no. Detected item detected failure condition check for c31 gear posi- tion signal gear position signal voltage should be higher than the following for 3 seconds and more. Gear position sensor voltage > 0.6 v if lower than the above value, c31 (p0705) is indicated. Gp sw...

  • Page 398

    14-46 vl800k5 (’05-model) “c12” (p0335) ckp sensor circuit malfunction inspection step 1 1) remove the left frame cover. ( $7-2) 2) remove the left frame lower cover 1 and tool box cover 2. 3) remove the tool box 3. 4) check the ckp sensor coupler 4 for loose or poor contacts. If ok, then measure th...

  • Page 399

    Vl800k5 (’05-model) 14-47 5) disconnect the ckp sensor coupler and measure the resis- tance. ! Ckp sensor resistance: 184 – 276 Ω (blue – green) 6) also, check the continuity between each terminal and ground. ! Ckp sensor continuity: ∞ Ω (infinity) (blue – ground) (green – ground) " 09900-25008: mul...

  • Page 400

    14-48 vl800k5 (’05-model) step 2 1) disconnect the ckp sensor coupler. 2) crank the engine a few seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. ! Ckp sensor peak voltage: 4.0 v and more ( + green – - blue) 1 peak volt adaptor 3) repeat the above test procedur...

  • Page 401

    Vl800k5 (’05-model) 14-49 “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction inspection step 1 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the iap sensor couplers (front cylinder side 1 or rear cylinder side 2) for loose or poor contacts. If ok, then measu...

  • Page 402

    14-50 vl800k5 (’05-model) step 2 1) connect the iap sensor couplers and install the fuel tank. 2) insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed and measure the iap sensor output voltage at the wire side coupler (between g/b and b/br wires or between g/w an...

  • Page 403

    Vl800k5 (’05-model) 14-51 is the voltage ok? 4) after repairing the trouble, clear the dtc using sds tool. ( $14-39) output voltage (vcc voltage 4.5 – 5.5 v, ambient temp. 20 – 30 °c, 68 – 86 °f) yes • g/b, g/w, r or b/br wire open or shorted to ground, or poor l, 3, 6 or d connection. • if wire and...

  • Page 404

    14-52 vl800k5 (’05-model) “c14” (p0120) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage. 4) disconnect...

  • Page 405

    Vl800k5 (’05-model) 14-53 step 1 (when indicating p0120-h:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuit...

  • Page 406

    14-54 vl800k5 (’05-model) step 1 (when indicating p0120-l:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, then check the tp sensor lead wire continuity. 4) disconnect the tp sensor coupler. 5) check the continuit...

  • Page 407

    Vl800k5 (’05-model) 14-55 step 2 1) turn the ignition switch off. 2) disconnect the tp sensor coupler. 3) check the continuity between yellow wire and ground. ! Tp sensor continuity: ∞ Ω (infinity) (yellow – ground) 4) if ok, then measure the tp sensor resistance at the termi- nals (between yellow w...

  • Page 408

    14-56 vl800k5 (’05-model) step 3 1) connect the tp sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage at the coupler (between + bl/b wire and - b/br wire) by turning the throttle grip. ! Tp sensor outp...

  • Page 409

    Vl800k5 (’05-model) 14-57 “c15” (p0115) ect sensor circuit malfunction inspection step 1 (when indicating c15:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor voltage at the wire side ...

  • Page 410

    14-58 vl800k5 (’05-model) step 1 (when indicating p0115-h:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler and ecm coupler. 5) ...

  • Page 411

    Vl800k5 (’05-model) 14-59 step 1 (when indicating p0115-l:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 4) disconnect the ect sensor coupler. 5) check the contin...

  • Page 412

    14-60 vl800k5 (’05-model) step 2 1) turn the ignition switch off. 2) measure the ect sensor resistance. ! Ect sensor resistance: approx. 2.3 – 2.6 k Ω at 20 °c (68 °f) (terminal – terminal) " 09900-25008: multi-circuit tester set % tester knob indication: resistance ( Ω ) 3) remove the ect sensor. 4...

  • Page 413

    Vl800k5 (’05-model) 14-61 “c21” (p0110) iat sensor circuit malfunction inspection step 1 (when indicating c21:) 1) remove the air cleaner box. ( $14-103) 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor voltage at the wir...

  • Page 414

    14-62 vl800k5 (’05-model) step 1 (when indicating p0110-h:) 1) remove the air cleaner box. ( $14-103) 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler and ecm coupl...

  • Page 415

    Vl800k5 (’05-model) 14-63 step 1 (when indicating p0110-l:) 1) remove the air cleaner box. ( $14-103) 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler. 5) check the...

  • Page 416

    14-64 vl800k5 (’05-model) step 2 1) turn the ignition switch off. 2) measure the iat sensor resistance. ! Iat sensor resistance: approx. 2.6 k Ω at 20 °c (68 °f) (terminal – terminal) " 09900-25008: multi-circuit tester set % tester knob indication: resistance ( Ω ) is the resistance ok? Note: iat s...

  • Page 417

    Vl800k5 (’05-model) 14-65 “c23” (p1651) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) remove the right frame cover. ( $7-2) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then measure the to sensor resistance. 4) disconn...

  • Page 418

    14-66 vl800k5 (’05-model) step 1 (when indicating p1651-h:) 1) remove the right frame cover. ( $7-2) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the con...

  • Page 419

    Vl800k5 (’05-model) 14-67 step 1 (when indicating p1651-l:) 1) remove the right frame cover. ( $7-2) 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the con...

  • Page 420

    14-68 vl800k5 (’05-model) step 2 1) connect the to sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between br/w and b/br wires. ! To sensor voltage: 0.4 – 1.4 v ( + br/w – - b/br) also, meas...

  • Page 421

    Vl800k5 (’05-model) 14-69 “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the stva lead wire coupler for loose or poor contacts. 4) remove the air intake pipe. ( $14-103) 5) turn the ignition switch on to c...

  • Page 422

    14-70 vl800k5 (’05-model) step 2 1) turn the ignition switch off. 2) disconnect the stva lead wire coupler. 3) check the continuity between each wire terminal and ground. ! Stva continuity: ∞ Ω (infinity) 4) if ok, then measure the stva resistance. (between black wire terminal and pink wire terminal...

  • Page 423

    Vl800k5 (’05-model) 14-71 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details) 2) turn the ignition switch on. 3) click “secondary throttle operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from stva, the f...

  • Page 424

    14-72 vl800k5 (’05-model) “c29” (p1654) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage. 4) disconn...

  • Page 425

    Vl800k5 (’05-model) 14-73 step 1 (when indicating p1654-h:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the contin...

  • Page 426

    14-74 vl800k5 (’05-model) step 1 (when indicating p1654-l:) 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the stp sensor coupler for loose or poor contacts. If ok, then check the stp sensor lead wire continuity. 4) disconnect the stp sensor coupler. 5) check the contin...

  • Page 427

    Vl800k5 (’05-model) 14-75 step 2 1) turn the ignition switch off. 2) disconnect the stp sensor coupler. 3) check the continuity between yellow wire terminal and ground. ! Stp sensor continuity: ∞ Ω (infinity) (yellow – ground) 6) if ok, then measure the stp sensor resistance at the coupler (between ...

  • Page 428

    14-76 vl800k5 (’05-model) step 3 1) turn the ignition switch off. 2) connect the stp sensor coupler. 3) insert the needle pointed probes to the stp sensor coupler. 4) disconnect the stva lead wire coupler. 5) turn the ignition switch on. 6) measure the stp sensor output voltage at the coupler (betwe...

  • Page 429

    Vl800k5 (’05-model) 14-77 is the voltage ok? 6) after repairing the trouble, clear the dtc using sds tool. ( $14-39) yes • y/w, r or b/br wire open or shorted to ground, or poor 4, 6 or d connection. • if wire and connection are ok, intermittent trou- ble or faulty ecm. • recheck each terminal and w...

  • Page 430

    14-78 vl800k5 (’05-model) “c31” (p0705) gp switch circuit malfunction inspection step 1 1) remove the left frame cover. ( $7-2) 2) remove the secondary gear case cover 1. 3) turn the ignition switch off. 4) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp switch vol...

  • Page 431

    Vl800k5 (’05-model) 14-79 5) support the motorcycle with a jack. 6) fold the side-stand to up position. 7) make sure the engine stop switch is in the “run” position. 8) insert the needle pointed probes to the lead wire coupler. 9) turn the ignition switch on. 10) measure the voltage at the wire side...

  • Page 432

    14-80 vl800k5 (’05-model) “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection step 1 1) remove the air intake pipe. ( $14-103) 2) turn the ignition switch off. 3) check the injector coupler for loose or poor contacts. If ok, then measure the injector resistance. 4) disconnect...

  • Page 433

    Vl800k5 (’05-model) 14-81 step 2 1) turn the ignition switch on. 2) measure the injector voltage between y/r wire and ground. ! Injector voltage: battery voltage ( + y/r – - ground) note: injector voltage can be detected only for 3 seconds after ignition switch is turned on. " 09900-25008: multi-cir...

  • Page 434

    14-82 vl800k5 (’05-model) “c41” (p0230) fp relay circuit malfunction inspection step 1 1) remove the secondary gear case cover 1. 2) turn the ignition switch off. 3) check the fp relay coupler for loose o poor contacts. 4) if ok, then check the insulation and continuity. Refer to page 96 for details...

  • Page 435

    Vl800k5 (’05-model) 14-83 “c49” (p1656) pair control solenoid valve circuit malfunction inspection step 1 1) remove the fuel tank. ( $14-93) 2) turn the ignition switch off. 3) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure the pair control solenoid val...

  • Page 436

    14-84 vl800k5 (’05-model) step 2 1) connect the pair control solenoid valve coupler. 2) turn the ignition switch on. 3) insert the needle pointed probes to the pair control solenoid valve coupler. 4) measure the voltage at the wire side coupler between black wire and ground. ! Pair control solenoid ...

  • Page 437

    Vl800k5 (’05-model) 14-85 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details) 2) turn the ignition switch on. 3) click “pair sol operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from the pair control sole...

  • Page 438

    14-86 vl800k5 (’05-model) “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (e-02, 19, 24) inspection step 1 (when indicating c44/p0130:) 1) remove the right frame cover. ( $7-2) 2) turn the ignition switch off. 3) check the ho2 sensor coupler for loose or poor contacts. If ok, then check th...

  • Page 439

    Vl800k5 (’05-model) 14-87 4) disconnect the ho2 sensor coupler and ecm coupler. 5) check the continuity between w/bl wire a and terminal 7. 6) also, check the continuity between w/bl wire a and ground. If sound of the continuity is not heard from the tester, the cir- cuit condition is ok. " 09900-25...

  • Page 440

    14-88 vl800k5 (’05-model) step 1 (when indicating c44/p0135:) 1) remove the right frame cover. ( $7-2) 2) turn the ignition switch off. 3) check the ho2 sensor coupler for loose or poor contacts. 4) insert the needle pointed probes to the ho2 sensor coupler. 5) turn the ignition switch on and measur...

  • Page 441

    Vl800k5 (’05-model) 14-89 step 2 (when indicating c44/p0135:) 1) turn the ignition switch off. 2) disconnect the ho2 sensor coupler. 3) check the resistance between the terminals (white – white) of the ho2 sensor. ! Ho2 heater resistance: 6.5 – 8.9 Ω (at 23 °c/73.4 °f) (white – white) note: * temper...

  • Page 442: Sensors

    14-90 vl800k5 (’05-model) sensors ckp sensor inspection the crankshaft position sensor is installed in the generator cover. ( $14-46) ckp sensor removal and installation • remove the generator cover. ( $3-18) • install the generator cover in the reverse order of removal. Iap sensor inspection the in...

  • Page 443

    Vl800k5 (’05-model) 14-91 iat sensor inspection the intake air temperature sensor is installed at the back side of the air cleaner box. ( $14-61) iat sensor removal and installation • remove the air cleaner box. ( $14-103) • remove the iat sensor from the air cleaner box. • install the iat sensor in...

  • Page 444: Fuel Delivery System

    14-92 vl800k5 (’05-model) fuel delivery system the fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump...

  • Page 445: Fuel System

    Vl800k5 (’05-model) 14-93 fuel system fuel tank lift-up • remove the seat. ( $7-2) • remove the fuel tank mounting bolt 1. • lift and support the fuel tank about 10 cm (3.94 in) with the prop stay. Note: be careful not to lift the fuel tank more than about 10 cm (3.94 in), or hoses will be twisted. ...

  • Page 446

    14-94 vl800k5 (’05-model) fuel pressure inspection • lift and support the fuel tank. ( $14-93) • place a rag under the fuel feed hose. • remove the fuel feed hose 1. • install the special tools between the fuel tank and fuel delivery pipe. " 09940-40211: fuel pressure gauge adaptor 09940-40220: fuel...

  • Page 447

    Vl800k5 (’05-model) 14-95 fuel pump inspection turn the ignition switch on and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor. Fuel discharge amount inspectio...

  • Page 448

    14-96 vl800k5 (’05-model) fuel pump relay inspection fuel pump relay is located inside the secondary gear case cover. • remove the secondary gear case cover. • remove the fuel pump relay 1. First, check the insulation between a and b terminals with pocket tester. Then apply 12 volts to c and d termi...

  • Page 449

    Vl800k5 (’05-model) 14-97 fuel pump construction 1 fuel pump 4 fuel mesh filter cover * 2 plate assy 5 fuel feed hose item n·m kgf-m lb-ft 3 fuel mesh filter a fuel pump mounting bolt a 10 1.0 7.0

  • Page 450

    14-98 vl800k5 (’05-model) fuel pump removal and disassembly • remove the fuel tank. ( $14-93) • remove the fuel pump assembly 1 by removing its mounting bolts diagonally. + • remove the fuel mesh filter cover 2. • disconnect the fuel pump coupler 3. • remove the screw 4 and fuel pump holder 5. • sep...

  • Page 451

    Vl800k5 (’05-model) 14-99 • remove the fuel mesh filter 7 and rubber cushion 8. Fuel mesh filter inspection and cleaning if the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air. Note: if t...

  • Page 452

    14-100 vl800k5 (’05-model) fuel pump reassembly and installa- tion install the fuel pump in the reverse order of removal and disas- sembly. Pay attention to the following points: • install a new bushing 1 to the fuel pump. # use the new bushing to prevent fuel leakage..

  • Page 453

    Vl800k5 (’05-model) 14-101 • install a new o-ring and apply suzuki super grease “a” to it. , 99000-25030: suzuki super grease “a” (usa) 99000-25010: suzuki super grease “a” (others) + • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the spe...

  • Page 454: Throttle Body

    14-102 vl800k5 (’05-model) throttle body construction 1 stp sensor 9 three way joint (only e33) 2 tp sensor 0 hose (only e33) 3 iap sensor a vacuum hoses 4 stva b fast idle screw 5 fuel delivery pipe c throttle stop screw * 6 o-ring a stp sensor mounting screw item n·m kgf-m lb-ft 7 fuel injector b ...

  • Page 455

    Vl800k5 (’05-model) 14-103 air cleaner box removal • remove the fuel tank. ( $14-93) • remove the bolts 1 and lossen the clamp screw 2. Note: “ ✩” indicates hook location. • disconnect the iat sensor lead wire coupler 3. • disconnect the pair hose 4. • remove the iap sensors (front cylinder side 5 a...

  • Page 456

    14-104 vl800k5 (’05-model) throttle body removal • remove the air intake pipe. ( $14-103) • disconnect the tp sensor lead wire coupler 1, stva lead wire coupler 2 and stp sensor lead wire coupler 3. • disconnect the fuel injector lead wire couplers 4. • disconnect the vacuum hoses 5. • loosen the th...

  • Page 457

    Vl800k5 (’05-model) 14-105 throttle body disassembly • remove the vacuum hose 1 and fuel feed hose 2. • remove the clamp 3. • remove the fuel delivery hose 4. • remove the fuel delivery pipes 5. • remove the fuel injectors 6 • remove the tp sensor 7 with the special tool. " 09930-11950: torx wrench ...

  • Page 458

    14-106 vl800k5 (’05-model) • remove the stp sensor 8 with the special tool. " 09930-11950: torx wrench note: * prior to disassembly, mark the stp sensor’s original position with a paint or scribe for accurate reinstallation. * tp sensor and stp sensor look very much alike. To avoid confusion, mark i...

  • Page 459

    Vl800k5 (’05-model) 14-107 throttle body cleaning + • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. # inspection • check following items for any damage or clogging * o-ring * throttle valve * secondary throttle valve * vacuum hose some carburetor cleani...

  • Page 460

    14-108 vl800k5 (’05-model) throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • apply thin coat of the engine oil to the new o-rings. # • with the stv fully opened, install the stp sensor 1 and tighten the stp sensor mo...

  • Page 461

    Vl800k5 (’05-model) 14-109 • install the o-ring and dust seal to each fuel injector. • apply thin coat of the engine oil to the new o-ring and cushion seal. # • install the fuel injectors 3 by pushing them straight to each throttle body. # • install the fuel delivery pipes 4 to the throttle body ass...

  • Page 462

    14-110 vl800k5 (’05-model) throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the tp sensor lead wire coupler 1. # • connect the throttle pulling cable 2 and throttle returning cable 3 to the throttle cable drum. • adjust the ...

  • Page 463

    Vl800k5 (’05-model) 14-111 stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor resistance and adjust the stp sensor position as follows: • disconnect the stp sensor coupler. • close the secondary throttle valve fully by moving the fast idle link, and measure the stp s...

  • Page 464

    14-112 vl800k5 (’05-model) fuel injector inspection check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. The fuel injector can be checked without removing it from the throttle body. Refer to page 80 for d...

  • Page 465

    Vl800k5 (’05-model) 14-113 fast idle the fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, d...

  • Page 466

    14-114 vl800k5 (’05-model) • calculate the voltage difference between tp sensor output voltage at idle and tp sensor output voltage with the stv full opened. Example: tp sensor output voltage with the stv fully open minus tp sensor output voltage at idle is 0.08 v ! Tp sensor output voltage variatio...

  • Page 467

    Vl800k5 (’05-model) 14-115 throttle valve synchronization check and adjust the throttle valve synchronization among two cylinders. Use of digital vacuum tester step 1 • lift and support the fuel tank. ( !14-93) • start up the engine and run it in idling condition for warming up. • stop the warmed-up...

  • Page 468

    14-116 vl800k5 (’05-model) step 3 • turn in two idle air screws to the complete close position. • check for difference of vacuum between front cylinder and rear cylinder. • equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower. ...

  • Page 469

    Vl800k5 (’05-model) 14-117 • connect a tachometer. • start up the engine and keep it running at 1 100 rpm by turn- ing throttle stop screw 2. # • turn the air screw 3 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 4 in the tube to the center line 5. Note: t...

  • Page 470

    14-118 vl800k5 (’05-model) throttle position sensor (tps) setting after all adjustments are completed, check or adjust the tps 1 setting condition..

  • Page 471: Emission Control Systems

    Vl800k5 (’05-model) 14-119 emission control systems fuel injection system vl800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 fuel tank 7 f...

  • Page 472

    14-120 vl800k5 (’05-model) exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and three-way catalyst sys- tem (for e-02, -19, -24 and -33). The fresh air is drawn into the exhaust port with the pair control solenoid valve and pair reed va...

  • Page 473

    Vl800k5 (’05-model) 14-121 noise emission control system tampering with the noise control system prohibited: federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any d...

  • Page 474: Inspection

    14-122 vl800k5 (’05-model) pair (air supply) system and emission control system inspection pcv hose • remove the pcv hose from the crankcase breather cover. • inspect the pcv hose for wear or damage. • if it is worn or damaged, replace the pcv hose with a new one. Pair hoses • inspect the pair hoses...

  • Page 475

    Vl800k5 (’05-model) 14-123 pair control solenoid valve • lift and support the fuel tank. ( $14-93) • remove the pair control solenoid valve cover 1. • disconnect the pair control solenoid valve lead wire coupler 2. • disconnect the pair hoses. • remove the pair control solenoid valve 3. • check that...

  • Page 476: (Only For E-33)

    14-124 vl800k5 (’05-model) evaporative emission control system inspection (only for e-33) • remove the seats 1. ( $7-2) • remove the speedometer 2. ( $5-3) • remove the fuel tank 3. ( $14-93) • remove the fuel frame cover 4. ( $7-2) hoses (evap hose) inspect the hoses for wear or damage. Make sure t...

  • Page 477: Tightening Torque

    Vl800k5 (’05-model) 14-125 tightening torque chassis item n·m kgf-m lb-ft front axle 65 6.5 47.0 front axle pinch bolt 33 3.3 24.0 brake disc bolt 23 2.3 16.5 front fork cap bolt 45 4.5 33.1 front fork spring stopper nut 35 3.5 25.5 front fork damper rod bolt 20 2.0 14.5 *front fork upper clamp bolt...

  • Page 478

    14-126 vl800k5 (’05-model) wiring harness, cable and hose routing wiring harness routing 50 mm 200 mm *1 *1 regulator/rectifier electrical parts holder fuse to generator to wiring harness 200 mm wiring harness generator leadwire clamp clamp clamp clamp clamp clamp wiring harness wiring harness front...

  • Page 479

    Vl800k5 (’05-model) 14-127 injector iat sensor frame wiring harness radiator 28 mm to speedometer to stoplamp switch to horn clamp clamp pass through inside of the cover to sensor to ho2s sensor.

  • Page 480

    14-128 vl800k5 (’05-model) star ter motor oil pressure s witch star ter motor lead wire 20 ˚ – 45 ˚ 80 ˚ – 110 ˚ 30 ˚ – 60 ˚ 90 ˚ cr ankcase r) clamp clamp clamp gener ator lead wire.

  • Page 481

    Vl800k5 (’05-model) 14-129 cable routing clutch cable *3 cable guide *1 wiring harness throttle cable clamp cable guide throttle cable no.1 (pulling cable) throttle cable no.2 (returning cable) brake hose wiring harness white tape clutch cable *4 clutch cable clamp clamp clamp high-tension cord cush...

  • Page 482

    14-130 vl800k5 (’05-model) cooling system hose routing hose clamp bolt tightening torque: 1.5 n·m (0.15 kgf-m, 1.0 lb-ft) p ass through the breather hose betw een the fr ame and stv a. Clamp the clamp bolt head should face bac kw ard. The ends of the clamp should f ace left side . Align the clamp an...

  • Page 483

    Vl800k5 (’05-model) 14-131 speed sensor lead wire routing brake hose speed sensor lead wire *1 headlight housing 30 mm (1.18 in) speed sensor lead guide speed sensor guide hook speed sensor lead wire clamp *1 pass through the speed sensor lead wire between the headlight housing and brake hose..

  • Page 484

    14-132 vl800k5 (’05-model) fuel tank installation frame cut the clamp.

  • Page 485

    Vl800k5 (’05-model) 14-133 brake pedal installation handlebar balancer *1 5 mm (0.20 in) 98 mm (3.86 in) *1 apply an adhesive agent. Handlebar throttle grip handle balancer expander handlebar balancer screw nut 5.5 n·m (0.5 kgf-m, 4.0 lb-ft) 1 mm (0.04 in): right side 0 mm (0 in): left side.

  • Page 486

    14-134 vl800k5 (’05-model) pair (air supply) system diagram *3 *1 *2 1 pair control solenoid valve *1 from air cleaner. 2 pair reed valve *2 to #1 cylinders. A fresh air *3 to #2 cylinders..

  • Page 487

    Vl800k5 (’05-model) 14-135 pair (air supply) system hose routing *2 *2 *1 *3 *5 *4 1 pair control solenoid valve *2 matching mark 2 throttle body *3 do not contact the hose and throttle cable drum. 3 bolt *4 the sealant side should face pair pipe side. *1 to air cleaner box. *5 with the bolt lightly...

  • Page 488

    14-136 vl800k5 (’05-model) evap canister hose routing (only for e-33) *3 *1 *2 1 three way joint 5 evap canister 2 wiring harness *1 pass through the purge hose over the wiring harness. 3 frame *2 white paint mark should face upside. 4 fuel shut-off valve *3 to three way joint..

  • Page 489: Fuel Feed Hose Routing

    Vl800k5 (’05-model) 14-137 fuel feed hose routing 1 iap sensor (front cylinder) 2 iap sensor (rear cylinder) 3 pcv (breather) hose 4 fuel feed hose *1 match mark (white) *1.

  • Page 490: Special Tools

    14-138 vl800k5 (’05-model) special tools note: when ordering the special tool, please confirm whether it is available or not. 09900-25009 needle pointed probe set 09904-41010 sds set 99565-01010-004 cd-rom ver.4 09913-13121 vacuum balancer gauge 09930-11950 torx wrench 09930-82720 mode select switch...

  • Page 491

    Vl800k5 (’05-model) 14-139 wire color b : black gr : gray r : red bl : blue lbl : light blue w : white br : brown lg : light green y : yellow dg : dark green o : orange g : green p : pink b/bl : black with blue tracer b/br : black with brown tracer b/g : black with green tracer b/lg : black with lig...

  • Page 493: Vl800Tk5 (’05-Model)

    Vl800tk5 (’05-model) 15- 1 contents vl800tk5 (’05-model) 15 this chapter describes service specifications, service data and servicing procedures which dif- fer from those of the vl800k5 (’05-model). Note: * any differences between the vl800k5 (’05-model) and vl800tk5 (’05-model) in specifi- cations ...

  • Page 494: Specifications

    15-2 vl800tk5 (’05-model) specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width ....................................................................................... 985 mm (38.8...

  • Page 495: Service Data

    Vl800tk5 (’05-model) 15-3 service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015)...

  • Page 496

    15-4 vl800tk5 (’05-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex....

  • Page 497

    Vl800tk5 (’05-model) 15-5 conrod + crankshaft unit: mm (in) oil pump piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469) — ...

  • Page 498

    15-6 vl800tk5 (’05-model) clutch unit: mm (in) transmission unit: mm (in) except ratio shaft drive unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/4 turn back — drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.42 – 3.58 (0....

  • Page 499

    Vl800tk5 (’05-model) 15-7 thermostat + radiator + fan + engine coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temper- ature approx. 75 °c (167 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — ect sensor resistance 2...

  • Page 500

    15-8 vl800tk5 (’05-model) fi senors+ secondary throttle valve actuator item specification note ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 4.0 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor input voltage 4.5...

  • Page 501

    Vl800tk5 (’05-model) 15-9 throttle body electrical unit: mm (in) item specification bore size 34 mm i.D. No. 41f1 (for e-33), 41f0 (for the others) idle r/min 1 100 ± 100 r/min fast idle r/min 2 100 r/min (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note fi...

  • Page 502

    15-10 vl800tk5 (’05-model) wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 w ← ← lo 55 w ← ← position/parking light 4 w brake light/taillight 21/5 w ← ← turn signal light 21/5 w (front), 21 w (rear) 21 w ← speedometer light led ← ← engine coola...

  • Page 503

    Vl800tk5 (’05-model) 15-11 tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front * 225 kpa (2.25 kgf/cm², 33 psi) — rear 250 kpa (2.50 kgf/cm², 36 psi) — cold inflation tire pressure (dual riding) front * 225 kpa (2.25 kgf/cm², 33 psi) — rear 250 kpa (2.5...

  • Page 504

    15-12 vl800tk5 (’05-model) fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with ...

  • Page 505: Vl800

    This chapter describes service specifications, service data and servicing p ocedures which dif- fer from those of the vl800tk5 (’05-model). Note:*any differences between the vl800tk6 (’06-model) and vl800tk5 (’05-model) in specifications and service data are indicated with an asterisk mark (*). *ple...

  • Page 506: Specifications

    Specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width........................................................................................ 985 mm (38.8 in) overall height .........

  • Page 507: Service Data

    Service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.057 (0.00...

  • Page 508

    Camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. 36.52 – 36.62 (1.438 – 1....

  • Page 509

    Conrod + crankshaft unit: mm (in) oil pump piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469) — piston pin bore 20.002 – 2...

  • Page 510

    Clutch unit: mm (in) transmission unit: mm (in) except ratio shaft drive unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/4 turn back — drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.42 – 3.58 (0.135 – 0.141) 3.12 (0.123) ...

  • Page 511

    Thermostat + radiator + fan + engine coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temper- ature approx. 75 °c (167 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — ect sensor resistance 20 °c (68 °f) approx. 2.45 ...

  • Page 512

    Fi senors+ secondary throttle valve actuator item specification note ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 4.0 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor resista...

  • Page 513

    Throttle body electrical unit: mm (in) item specification bore size 34 mm i.D. No. 41f1 (for e-33), 41f0 (for the others) idle r/min 1 100 ± 100 r/min fast idle r/min 2 100 r/min (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firing order 1·2 spark plug ...

  • Page 514

    Wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 w ← ← lo 55 w ← ← position/parking light 4 w brake light/taillight 21/5 w ← ← turn signal light 21/5 w (front), 21 w (rear) 21 w ← speedometer light led ← ← engine coolant temp. Warning light led ...

  • Page 515

    Tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front vl800 200 kpa (2.00 kgf/cm², 29 psi) — vl800t 225 kpa (2.25 kgf/cm², 33 psi) rear 250 kpa (2.50 kgf/cm², 36 psi) — cold inflation tire pressure (dual riding) front vl800 200 kpa (2.00 kgf/cm², 29 psi) ...

  • Page 516: Special Tools

    Fuel + oil special tools item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with appropriate c...

  • Page 517: Conrod/crankshaft

    Conrod/crankshaft crankcase/crankshaft bearing inspection • inspect the crankshaft and crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. • measure the crankshaft journal o.D. 1 by using the special tool. ! Crankshaft journal o.D. 1 standard: 47.965 – ...

  • Page 518

    Bearing thickness # crankshaft journal bearing replacement use the special tool to replace the crankshaft journal bearings. The replacement procedure is as follows: " 09913-60230: journal bearing remover/installer • set the special tool as shown to remove the crankshaft journal bearings. Note: remov...

  • Page 519

    Note: using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools. " 09924-84510: bearing installer set 09924-74570: final drive gear bearing remover/installer • set the specified cra...

  • Page 520

    • set the bearings installed in the special tool to the crankcase half as shown. # note: the upper and lower bearings are same. • insert the thickness gauge 1 between the special tool 2 and 3 for 1 mm (0.04 in) clearance. • apply enough engine oil to the special tool and the bearings and then set th...

  • Page 521

    Note: using the hand-press is recommended to install the crankshaft journal bearings. However, the crankshaft journal bearings can be installed by using the following special tools. " 09924-84510: bearing installer set 09924-74570: final drive gear bearing remover/installer • after installing the be...

  • Page 522: Emission Control Systems

    Emission control systems exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and three-way catalyst sys- tem. The fresh air is drawn into the exhaust port with the pair control solenoid valve and pair reed valve. The pair control solenoid ...

  • Page 523: Vl800/tk7 (’07-Model)

    Specifications and service data are indicated with an asterisk mark (*). Contents specifications.... ............................................................................... 2 service data ...................................................................................... 3 17 this chapter...

  • Page 524: Specifications

    Specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width........................................................................................* 970 mm (38.2 in) overall height ........

  • Page 525: Service Data

    Service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.057 (0.00...

  • Page 526

    Camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height front in. 35.95 – 35.99 (1.415 – 1.417) 35.65 (1.404) ex. 36.92 – 36.96 (1.454 – 1.455) 36.62 (1.442) rear in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. 36.52 – 36.62 (1.438 – 1....

  • Page 527

    Conrod + crankshaft unit: mm (in) oil pump piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469) — piston pin bore 20.002 – 2...

  • Page 528

    Clutch unit: mm (in) transmission unit: mm (in) except ratio shaft drive unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/4 turn back — drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.42 – 3.58 (0.135 – 0.141) 3.12 (0.123) ...

  • Page 529

    Thermostat + radiator + fan + engine coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temper- ature approx. 75 °c (167 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — ect sensor resistance 20 °c (68 °f) approx. 2.45 ...

  • Page 530

    Fi senors+ secondary throttle valve actuator item specification note ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 4.0 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sensor input voltage 4.5 – 5.5 v tp sensor resista...

  • Page 531

    Throttle body electrical unit: mm (in) item specification bore size 34 mm i.D. No. 41f1 (for e-33), 41f0 (for the others) idle r/min 1 100 ± 100 r/min fast idle r/min 2 100 r/min (when cold engine) throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) item specification note firing order 1·2 spark plug ...

  • Page 532

    Wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 w ← ← lo 55 w ← ← position/parking light 4 w brake light/taillight 21/5 w ← ← turn signal light 21/5 w (front), 21 w (rear) 21 w ← speedometer light led ← ← engine coolant temp. Warning light led ...

  • Page 533

    Tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front vl800 200 kpa (2.00 kgf/cm², 29 psi) — vl800t 225 kpa (2.25 kgf/cm², 33 psi) rear 250 kpa (2.50 kgf/cm², 36 psi) — cold inflation tire pressure (dual riding) front vl800 200 kpa (2.00 kgf/cm², 29 psi) ...

  • Page 534

    Fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and ...

  • Page 535

    Fuel pump and fuel level gauge removal removal • remove the fuel tank. ( !Vl800k5-93) • remove the fuel pump assembly 1 mounting bolts diago- nally. " • disconnect the fuel gauge lead wire coupler 2 before remove the fuel pump assembly. • remove the fuel level gauge 3 from the fuel tank by pushing t...

  • Page 536: Installation

    Fuel pump and fuel level gauge installation install the fuel pump and fuel level gauge in the reverse order of removal and disassembly. Pay attention to the following points: • install the fuel level gauge 1 into the fuel tank. Note: push the lock portion a fully until the clicking sound heard. • in...

  • Page 537: Fuel Level Gauge Inspection

    Fuel level gauge inspection • remove the fuel level gauge assembly. • measure the resistance at each fuel level gauge float position. If the resistance is incorrect, replace the fuel level gauge with a new one. ' 09900-25008: multi-circuit tester set ( tester knob indication: resistance (Ω) float po...

  • Page 538: Cable Routing

    Cable routing brake hose clutch cable handle switch rh harness throttle cable no.1 throttle cable no.2 handle switch lh harness 300 mm 0 mm clamp direction cushion clamp direction high tension cord high tension cord clutch cable clamp to the cushion. Solenoid harness 0 mm clutch cable clamp do not h...

  • Page 539: Front Brake Hose Routing

    Front brake hose routing 35˚ 28˚ p ass the br ak e hose through the hose guides . Speed sensor lead wire inser t the projection on the br ak e hose clamp into the hole of the steer ing stem lo w er br ac k et. Br ak e caliper speed sensor lead wire guide clamp the br ak e hose fir mly after touching...

  • Page 541: Vl800/c/ Tk9 (’09-Model)

    8.%6- ŏ/1&'. Contents vl800/c/ tk9 (’09-model) © copyright suzuki motor corporation 2008 4his information describes service data service specifications &) and servicing procedures which differ from those of the 6,#4+ model note: • any differences between the vl800/c/tk8 (’08-model) and vl800/c/tk9 (...

  • Page 542: Vl800/c/ Tk9 (’09-Model)

    18-2 vl800/c/tk9 (’09-model) vl800/c/ tk9 (’09-model) contents throttle body reassembly.......................................................... 18-46 throttle body installation ........................................................ 18-50 stp sensor adjustment........................................

  • Page 543: Sae-to-Former Suzuki Term

    Vl800/c/tk9 (’09-model) 18-3 abbreviations used in this manual note: please refer to the vl800 (’06-model) service manual and vl800/c/t (’07/’08-models) service informations for other abbreviations which are not given in this manual. E evap : evaporative emission i isc valve : idle speed control val...

  • Page 544: Specifications

    18-4 vl800/c/tk9 (’09-model) specifications dimensions and curb mass overall length ......................................................................................* 2 500 mm (98.4 in) overall width .......................................................................................* 955 mm...

  • Page 545

    Vl800/c/tk9 (’09-model) 18-5 periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and months for your...

  • Page 546

    18-6 vl800/c/tk9 (’09-model) maintenance and tune-up procedures this section describes the servicing procedures for each peri- odic maintenance item which differ from those of the vl800k6 (’06-model). For details other than the following items, refer to the vl800 service manual. Air cleaner • remove...

  • Page 547

    Vl800/c/tk9 (’09-model) 18-7 • remove the air cleaner element 6. • carefully use compressed air to clean the air cleaner element. • reinstall the cleaned or new air cleaner element in he reverse order of removal. Note: when cleaning the air cleaner element, drain water from the air cleaner by removi...

  • Page 548

    18-8 vl800/c/tk9 (’09-model) spark plug no.2 (front) spark plug removal (for e-02, 19, 24, 33) • remove the air cleaner. ( page 18-6) • remove the air cleaner bracket 1. • remove the cylinder head cover cap bolt 2. • open the cylinder head cover cap 3 as shown. • disconnect the spark plug caps 4. •...

  • Page 549

    Vl800/c/tk9 (’09-model) 18-9 • place a rug on the cylinder head cap 2. • open the cylinder head cover cap 2 as shown. • disconnect the spark plug caps 3. • remove the spark plugs 4 with the special tools. 09930-10121: spark plug socket wrench set 09930-14530: universal joint no.1 (rear) spark plug r...

  • Page 550

    18-10 vl800/c/tk9 (’09-model) spark plug gap • measure the plug gap with a thickness gauge. If out of specifi- cation, adjust it to the following gap. 09900-20803: thickness gauge spark plug gap a standard: 0.6 – 0.7 mm (0.024 – 0.028 in) ...................For e-02, 19, 24, 33 0.8 – 0.9 mm (0.031 –...

  • Page 551

    Vl800/c/tk9 (’09-model) 18-11 valve clearance valve clearance must be checked and adjusted when: (1) the valve mechanism is service, and (2) the camshafts are serviced. Check and adjust the clearance to the specification. Valve clearance (when cold): in. 0.08 – 0.13 mm (0.003 – 0.005 in) ex. 0.17 – ...

  • Page 552

    18-12 vl800/c/tk9 (’09-model) • remove the pair pipe bolts (rear cylinder). • remove the gasket 5. • remove the inspection caps. • remove the generator cover plug 6. • remove the cap 7 and timing inspec ion plug 8. • rotate the generator rotor to set the no.1 (rear) cylinder at tdc of the compressio...

  • Page 553

    Vl800/c/tk9 (’09-model) 18-13 • to inspect the no.1 (rear) cylinder valve clearance, insert the thickness gauge to the clearance between the valve stem end and the adjusting screw on the rocker arms. 09900-20806: thickness gauge • if the clearance is out of the specification, bring it into the speci...

  • Page 554

    18-14 vl800/c/tk9 (’09-model) engine oil and oil filter oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change. Engine oil replacement • remove the engine under cover 1 by removing the fasten- ers. (for e-02, ...

  • Page 555

    Vl800/c/tk9 (’09-model) 18-15 • start up the engine and allow it to run for several minutes at idling speed. • turn off the engine and wait about three minutes, then check the oil level through the inspection window a. If the level is below mark “l”, add oil to “f” level. If the level is above mark ...

  • Page 556

    18-16 vl800/c/tk9 (’09-model) throttle cable play adjust the throttle cable play a as follows. • loosen the lock-nut 2 of the throttle pulling cable 1. • turn the adjuster 3 in or out until the throttle cable play (at the throttle grip) a is between 2.0 – 4.0 mm (0.08 – 0.16 in). • tighten the lock-...

  • Page 557: Compression Pressure Check

    Vl800/c/tk9 (’09-model) 18-17 compression pressure check the compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compr...

  • Page 558: Fi System Diagnosis

    18-18 vl800/c/tk9 (’09-model) fi system diagnosis fi system wiring diagram iaps (f ront) iaps (rear) ects ia ts ho2s (f ront) ho2s (rear) stps ckps tps speedometer g/y br r b /b g/b g/w b/bl dg b/br br/w w/b w/bl to s isc v alv e ecm fuel pump fuel injector #1 #2 ignition coil 10 a 20 a 30 a 10 a si...

  • Page 559

    Vl800/c/tk9 (’09-model) 18-19 ecm terminal terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) h — 2 iat sensor signal (iat) i ect sensor signal (ect) 3 iap sensor signal #2 (iap. F) j to sensor signal (tos) 4 stp sensor signal (stp) k tp sensor signal (tp) 5 power source for sensors (...

  • Page 560: Fail-Safe Function

    18-20 vl800/c/tk9 (’09-model) fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from ...

  • Page 561

    Vl800/c/tk9 (’09-model) 18-21 dtc table and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mechan- ical part...

  • Page 562

    18-22 vl800/c/tk9 (’09-model) dtc no. Detected item detected failure condition check for c23 to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v sensor voltage in other than the above value, c23 (p1651) is indicated. To sensor, lead...

  • Page 563

    Vl800/c/tk9 (’09-model) 18-23 note: ho2 sensor voltage measuring condition * warm up the engine as follows: 10 minutes at idling or 100 seconds over 2 000 r/min. * coolant temperature is upper 45 °c (113 °f). Dtc no. Detected item detected failure condition check for c40/p0505 isc valve the circuit ...

  • Page 564

    18-24 vl800/c/tk9 (’09-model) dtc troubleshooting “c12” (p0335) ckp sensor circuit malfunction on model k9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to page 14-46 for details. “...

  • Page 565

    Vl800/c/tk9 (’09-model) 18-25 “c21” (p0110-h/l) iat sensor circuit malfunction on model k9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to page 14-61 for details. “c23” (p1651-h/l)...

  • Page 566

    18-26 vl800/c/tk9 (’09-model) “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool step 1 (when indicating c32/p0201 for fuel injector #1) (when indicating c33/p0202 for fuel injector #2) 1) turn the ignition swit...

  • Page 567

    Vl800/c/tk9 (’09-model) 18-27 6) if ok, then check the continuity between each terminal and ground. Stp sensor continuity: ∞ Ω (infinity) 09900-25008: multi-circuit tester set tester knob indication: resistance ( Ω ) are the resistance and continuity ok? Step 2 1) turn the ignition switch on. 2) mea...

  • Page 568

    18-28 vl800/c/tk9 (’09-model) “c40” (p0505/p0506/p0507) isc valve circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) remove the fuel tank. (  page 14-93) 3) check the isc valve coupler for loose or poor contacts...

  • Page 569

    Vl800/c/tk9 (’09-model) 18-29 4) disconnect the isc valve coupler and ecm coupler. 5) check the continuity between terminals a and g, terminals b and ^, terminals c and i, terminals d and \. Isc valve wire continuity: continuity ( ) 09900-25008: multi-circuit tester set 09900-25009: needle pointed p...

  • Page 570

    18-30 vl800/c/tk9 (’09-model) active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 09904-41010: sds set tool 99565-01010-017: cd-rom ver.17 2) check that the engine is running. 3) click the “active control”. 4) click the...

  • Page 571

    Vl800/c/tk9 (’09-model) 18-31 check 3 1) click the button 1 and increase the “spec” 2 to 1 400 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2. Also, check that the number of steps 4 in the isc valve position increases . Check 4 1) click the button 1 and increase...

  • Page 572

    18-32 vl800/c/tk9 (’09-model) “c41” (p0230) fp relay circuit malfunction on model k9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to page 14-82 for details. “c42” (p1650) ig switch...

  • Page 573

    Vl800/c/tk9 (’09-model) 18-33 “c44” (p0156/p0161) or “c64” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24, 33) inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 (sensor circuit check) (when indicating c44/p0156 for ho2 sensor #1) (when indicati...

  • Page 574

    18-34 vl800/c/tk9 (’09-model) 7) disconnect the ecm coupler. 8) check the continuity between w/bl wire (#1) c and terminal w. (for ho2 sensor #1) check the continuity between w/g wire (#2) a and terminal 6. (for ho2 sensor #2) 9) also, check the continuity between b/br wire b and terminal b. Ho2 sen...

  • Page 575

    Vl800/c/tk9 (’09-model) 18-35 is the voltage ok? Step 1 (heater circuit check) (when indicating c44/p0161 for ho2 sensor #1) (when indicating c64/p0135 for ho2 sensor #2) 1) turn the ignition switch off. 2) remove the right frame cover. (for ho2 sensor #1) (  page 7-2) 3) check the ho2 sensor coupl...

  • Page 576

    18-36 vl800/c/tk9 (’09-model) step 2 (heater circuit check) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w (o/w) wire and ground. 4) if the tester voltage indicates the battery ...

  • Page 577

    Vl800/c/tk9 (’09-model) 18-37 “c62” (p0443) evap system purge control solenoid valve circuit malfunction (e-33 only) inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) remove the right frame cover. (  page 7-2) 3) check the purge c...

  • Page 578

    18-38 vl800/c/tk9 (’09-model) step 2 1) connect the purge control solenoid valve coupler. 2) turn the ignition switch on. 3) measure the voltage at the wire side coupler between o/w wire and ground. Pair control solenoid valve voltage: battery voltage ( + o/w – - ground) 09900-25008: multi-circuit t...

  • Page 579: Throttle Body

    Vl800/c/tk9 (’09-model) 18-39 throttle body construction e-33 only 1 stp sensor 0 air screw 2 o-ring a straight plug 3 tp sensor b iap sensor 4 isc valve c 3-way joint (e-33 only) item n·m kgf-m lbf-ft 5 delivery pipe a stp sensor mounting bolt a 3.5 0.35 2.5 6 straight joint b tp sensor mounting bo...

  • Page 580

    18-40 vl800/c/tk9 (’09-model) throttle body removal • remove the air cleaner box. ( page 18-8) • remove the iap sensors (front cylinder side 1 and rear cyl- inder side 2) from the mounting stay. • remove the pcv hose 3 and loosen the clamp screw 4. • remove the air cleaner outlet tube 5. • disconne...

  • Page 581

    Vl800/c/tk9 (’09-model) 18-41 • loosen the throttle body clamp screw at the intake pipe side. • move the throttle body upward. • disconnect the vacuum hoses a. • disconnect the hoses b. (for e-33) • disconnect the throttle cables from their drum. After disconnecting the throttle cables do not snap t...

  • Page 582

    18-42 vl800/c/tk9 (’09-model) throttle body disassembly • remove the fuel feed hose 1. • remove the clamp 2. • loosen the screw and remove the plate 3. • pull on the straight plug 4 straightly outward to remove it so as not to cause scratches on the o-ring seat of the delivery pipe. • screw an appro...

  • Page 583

    Vl800/c/tk9 (’09-model) 18-43 • when removing the fuel injector 7, pull it straightly so as not to cause scratches on the o-ring seat of delivery pipe. • remove the tp sensor 9 and stp sensor 0 with the special tool. 09930-11950: torx wrench note: prior to disassembly, mark each sensor’s original po...

  • Page 584

    18-44 vl800/c/tk9 (’09-model) never remove the stva b from the throttle body. Never remove the secondary throttle valve c and throttle valve d . The adjusting screw e is factory-adjusted at the time of delivery and do not turn or remove it..

  • Page 585

    Vl800/c/tk9 (’09-model) 18-45 throttle body cleaning • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. Throttle body inspection • check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose * fuel h...

  • Page 586

    18-46 vl800/c/tk9 (’09-model) throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • apply thin coat of engine oil to the o-ring. • connect the isc valve 1 to the isc lead wire coupler. • turn the ignition switch on and t...

  • Page 587

    Vl800/c/tk9 (’09-model) 18-47 • with the stv fully opened, install the stp sensor 2 and tighten the stp sensor mounting screw to the specified torque. Stp sensor 2: green color coupler note: * apply thin coat of engine oil to the new o-ring. * align the secondary throttle shaft end a with the groove...

  • Page 588

    18-48 vl800/c/tk9 (’09-model) • apply thin coat of engine oil to the new o-rings and cushion seals. • install the fuel injector 4 by pushing it straight to the delivery pipe 5. Note: align the coupler e of the injector with the groove f of the delivery pipe. • install the fuel delivery pipes 6 to th...

  • Page 589

    Vl800/c/tk9 (’09-model) 18-49 • before installing the straight joint 7, clean its inside and out- side. • apply thin coat of the engine oil to the o-rings. • insert both the straight joint 7 and straight plug 8 straightly into the delivery pipe. • tighten the straight plug mounting screw to the spec...

  • Page 590

    18-50 vl800/c/tk9 (’09-model) throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the sensor lead wire couplers. Tp sensor lead wire coupler 1: black • connect the throttle pulling cable 2 and throttle returning cable 3 to the ...

  • Page 591

    Vl800/c/tk9 (’09-model) 18-51 stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor out put voltage and adjust the stp sensor position as follows: • remove the fuel tank. (  page 14-93) • disconnect the stva coupler 1. • loosen the clamp screw and move the air cleaner ...

  • Page 592

    18-52 vl800/c/tk9 (’09-model) tp sensor adjustment after all adjustments are completed, check or adjust the tps setting condition. 1. Remove the right frame cover. (  page 7-2) 2. Connect the special tool (mode select switch) to the dealer mode coupler at the wiring harness. (  page 14-37) 3. Turn...

  • Page 593

    Vl800/c/tk9 (’09-model) 18-53 isc valve removal • remove the throttle body. ( page 18-40) • remove the isc valve 1. Isc valve installation install the isc valve in the reverse order of removal. Pay attention to the following points: isc valve inspection • inspect the isc valve for carbon deposition...

  • Page 594

    18-54 vl800/c/tk9 (’09-model) isc valve preset and opening initialization when removing or replacing the isc valve, set the isc valve in the following procedures: 1) turn the ignition switch on. 2) set up the sds tool. (refer to the sds operation manual for further details.) 09904-41010: sds set too...

  • Page 595

    Vl800/c/tk9 (’09-model) 18-55 throttle valve synchronization use of sds tool check and adjust the throttle valve synchronization between two cylinders. Step 1 • lift and support the fuel tank. (  page 14-93) • disconnect the vacuum hoses 1 from the throttle body. • connect the respective vacuum tes...

  • Page 596

    18-56 vl800/c/tk9 (’09-model) • click “active control”. • click “isc air volume control” 1. • click “on” bottom 2 to fix the isc air volume of two cylinders. Note: when making this synchronization, be sure that the water tem- perature is within 90 – 110 °c (194 – 230 °f). • check for the synchroniza...

  • Page 597: Ignition System

    Vl800/c/tk9 (’09-model) 18-57 ignition system inspection ignition coil primary peak voltage (for e-02, 19, 24, 33) • remove the fuel tank. (  page 14 93) • remove the frame head covers. (  page 3-3) • disconnect the spark plug caps ( page 18-8) • connect new spark plugs to each spark plug cap and...

  • Page 598

    18-58 vl800/c/tk9 (’09-model) measure the ignition coils primary peak voltage in the following procedures: • connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil (main): + probe: b/bl terminal - probe: ground #1 ignition coil (sub): + probe: b/r terminal - probe: g...

  • Page 599

    Vl800/c/tk9 (’09-model) 18-59 ignition coil primary peak voltage (for e-03, 28) for details other than the following, refer to the vl800 service manual 8-18. • connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil: + probe: b/bl terminal - probe: ground #2 ignition ...

  • Page 600: Combination Meter Inspection

    18-60 vl800/c/tk9 (’09-model) combination meter inspection led (light emitting diode) check that the led lights (fi indicator light, oil pressure indicator light and engine coolant indicator light) immediately after turning the ignition switch on. Also, other led lights (neutral indicator light, hig...

  • Page 601: Wiring Harness Routing

    Vl800/c/tk9 (’09-model) 18-61 wiring harness routing *1 cut off the excess end of the clamp. *6 do not pinch the wiring harness with pair pipe and water hose. *2 pass the starter motor lead wire inside of the coupler. *7 do not contact the plug cap(s) with cylinder head cover cap. *3 do not pass the...

  • Page 602

    18-62 vl800/c/tk9 (’09-model) *1 set the lead wire under the starter relay. *6 do not contact the plug cap(s) with cylinder head cover cap. *2 set the couplers inside of the frame. *7 pass the harness inside of the frame. *3 set the coupler behind the ig switch body. *8 pass the lead wire over the e...

  • Page 603

    Vl800/c/tk9 (’09-model) 18-63 star ter motor oil pressure s witch star ter motor lead wire 80˚ – 110˚ 30 60˚ cr ankcase (r) clamp clamp clamp gener ator lead wire 20˚ – 45˚ 90˚ 80˚ – 110˚ 10 n . M (1.0 kgf-m , 7.0 lbf-ft) don , t pinch the lead wire and coupler with gener ator co v er . 14 n . M (1....

  • Page 604

    18-64 vl800/c/tk9 (’09-model) *1 set the wire harness between the fender and fender brace. *2 set the wire harness between the fender and reinforcement. *3 cut the tip of clamp within 5 mm (0.2 in) from the lock part. Clamp fwd grommet clamp clamp *2 3* *3 *3 *1 10 mm (0.4 in).

  • Page 605: Cable Routing

    Vl800/c/tk9 (’09-model) 18-65 cable routing for e-02, 19, 24, 33 *1 when clamping, locate clutch cable so that its white tape comes closely adjacent to throttle cable bracket. *5 position the white tape of the clutch cable on the dent of the frame. *2 be careful not to contact the stopper of clamp a...

  • Page 606

    18-66 vl800/c/tk9 (’09-model) for e-03, 28 *1 when clamping, locate clutch cable so that its white tape comes closely adjacent to throttle cable bracket. *5 position the white tape of the clutch cable on the dent of the frame. *2 be careful not to contact the stopper of clamp and left side cover. *6...

  • Page 607: Throttle Body Installation

    Vl800/c/tk9 (’09-model) 18-67 throttle body installation *1 pass the vacuum hose over the outlet tube. Be careful not to pinch the vacuum hose between the stv actuator and tp sensor. *6 pass the ho2 sensor lead wire over the pillion footrest bracket. Pass the ho2 sensor lead wire between the side re...

  • Page 608: Ignition Coil Installation

    18-68 vl800/c/tk9 (’09-model) ignition coil installation for e-02, 19, 24, 33 1 ignition coil #1 (main) 2 ignition coil #1 (sub) item n·m kgf-m lbf-ft 3 ignition coil #2 (main) a 4.5 0.45 3.5 4 ignition coil #2 (sub) 5 protector a ignition coil bolt *1 when installing the rear ignition coil bracket,...

  • Page 609

    Vl800/c/tk9 (’09-model) 18-69 for e-03, 28 1 ignition coil #1 2 ignition coil #2 item n·m kgf-m lbf-ft 3 protector a 4.5 0.45 3.5 a ignition coil bolt *1 pass the spacer to the hole a of protector securely. Do not pinch the spacer between the protector and frame. *1.

  • Page 610: Engine Mounting

    18-70 vl800/c/tk9 (’09-model) engine mounting 79 n.M (7.9 kgf-m, 57.0 lbf-ft) 79 n.M (7.9 kgf-m 57 0 lbf-ft) 50 n.M (5.0 kgf-m, 36.0 lbf-ft) 50 n.M (5.0 kgf-m, 36.0 lbf-ft) 23 n.M (2.3 kgf-m, 16.5 lbf-ft) 25 n.M (2.5 kgf-m, 18.0 lbf-ft).

  • Page 611

    Vl800/c/tk9 (’09-model) 18-71 muffler & exhaust pipe installation 1 ho2 sensor (e-02, 19, 24, 33) *1 install the body c with inlaying the claw of mouthpiece into the slit of muffler clamp. Item n·m kgf-m lbf-ft a 23 2.3 16.5 2 body c 2 apply muffler seal [muffler seal loc- tite 5920 (commercially av...

  • Page 612

    18-72 vl800/c/tk9 (’09-model) pair (air supply) system hose routing *1 fit hose ends onto hose joint all the way until stopper flange is securely contacted. Align hose clamp end with matching mark. *4 tighten bolts with pair pipe slightly tensioned clockwise. *2 hose should not contact throttle valv...

  • Page 613

    Vl800/c/tk9 (’09-model) 18-73 rear combination light installation 1 rear turn signal light (lh) 7 rear combination light *1 install the cushion to the rear fender. 2 rear turn signal upper cover 8 rear fender 3 rear reflector 9 reinforcement 4 license plate light 0 cushion item n·m kgf-m lbf-ft 5 re...

  • Page 614: Special Tools

    18-74 vl800/c/tk9 (’09-model) special tools note: when order the special tool, please conf rm whether it is available or not. 09900-20803 09900-20806 thickness gauge 09900-25008 multi-circuit tester set 09900-25009 needle pointed probe set 09904-41010 sds set tool 09915-40620 oil filter wrench 09917...

  • Page 615: Tightening Torque

    Vl800/c/tk9 (’09-model) 18-75 tightening torque engine fi system and intake air system item n·m kgf-m lbf-ft driveshaft bolt 55 5.5 40.0 ignition coil bolt 4.5 0.45 3.5 spark plug 11 1.1 8.0 oil drain plug 21 2.1 15.0 oil pressure switch 14 1.4 10.0 generator rotor bolt 160 16.0 115.5 starter motor ...

  • Page 616: Service Data

    18-76 vl800/c/tk9 (’09-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve clearance (when cold) in. 0.08 – 0.13 (0.003 – 0.005) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.001...

  • Page 617

    Vl800/c/tk9 (’09-model) 18-77 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 35.50 – 35.54 (1.398 – 1.399) 35.20 (1.386) ex. 36.58 – 36.62 (1.440 – 1.442) 36.28 (1.428) camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0...

  • Page 618

    18-78 vl800/c/tk9 (’09-model) conrod + crankshaft unit: mm (in) oil pump piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469...

  • Page 619

    Vl800/c/tk9 (’09-model) 18-79 clutch unit: mm (in) transmission unit: mm (in) except ratio shaft drive unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) — clutch release screw 1/4 turn back — drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.42 – 3.58...

  • Page 620

    18-80 vl800/c/tk9 (’09-model) thermostat + radiator + fan + engine coolant injector + fuel pump + fuel pressure regulator item standard/specification note thermostat valve opening temperature approx. 75 °c (167 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — ect sensor resistance...

  • Page 621

    Vl800/c/tk9 (’09-model) 18-81 fi sensors + secondary throttle valve actuator throttle body item specification note ckp sensor resistance 184 – 276 Ω ckp sensor peak voltage 1.5 v and more when cranking iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.6 v at idle speed tp sens...

  • Page 622

    18-82 vl800/c/tk9 (’09-model) electrical unit: mm (in) item specification note firing order 1·2 spark plug type * ngk: dr7ea denso: x22esr-u for e-02, 19, 24, 33 ngk: dpr7ea-9 denso: x22epr-u9 for e-03, 28 gap * 0.6 – 0.7 (0.024 – 0.028) for e-02, 19, 24, 33 0.8 – 0.9 (0.031 – 0.035) for e-03, 28 sp...

  • Page 623

    Vl800/c/tk9 (’09-model) 18-83 wattage unit: w brake + wheel unit: mm (in) item specification e-03, 28, 33 e-24 others headlight hi 60 ← ← lo 55 ← ← position/parking light 5 brake light/taillight led ← ← turn signal light 21/5 (front), 21 (rear) 21 ← licence plate light 5 ← ← speedometer light led ← ...

  • Page 624

    18-84 vl800/c/tk9 (’09-model) tire suspension unit: mm (in) item standard limit cold inflation tire pressure (solo riding) front vl800 200 kpa (2.00 kgf/cm², 29 psi) ---- vl800c/t 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) ...

  • Page 625

    Vl800/c/tk9 (’09-model) 18-85 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol wi...

  • Page 626: Emission Control System

    18-86 vl800/c/tk9 (’09-model) emission control system exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system, ho2 sensor (for e-02, 19, 24, 33), catalyst system and isc system. The fresh air is drawn into the exhaust port through the pair con...

  • Page 627

    Vl800/c/tk9 (’09-model) 18-87 evaporative emission control system (only for e-33) 1 fuel-vapor separator 7 vacuum hose 2 surge hose 8 iap sensor 3 fuel shut-off valve a hc vapor 4 evap canister b fresh air 5 purge hose c vacuum 6 evap system purge control solenoid valve.

  • Page 628: (For E-02, 19, 24, 33)

    18-88 vl800/c/tk9 (’09-model) pair (air supply) system inspection hoses  page 14-122 pair reed valve  page 14-122 pair control solenoid valve  page 14-123 heated oxygen sensor (ho2s) inspection (for e-02, 19, 24, 33) page 18-33 evaporative emission control system inspection (only for e-33) hoses...

  • Page 629

    Vl800/c/tk9 (’09-model) 18-89 • remove the evap system purge control solenoid valve 5 from the purge control solenoid valve bracket. Note: evap system purge control solenoid valve can be checked with- out removing it. ( page 18-38) inspection • check that no air flows through both of the air inlet ...

  • Page 630

    18-90 vl800/c/tk9 (’09-model) fuel shut-off valve inspect the fuel shut-off valve body for damage. Inspect the fuel shut-off valve operation in the following proce- dure. • remove the right frame cover. ( page 7-2) • remove the purge control solenoid valve bracket. ( page 18-86) • remove the fuel ...

  • Page 631

    Vl800/c/tk9 (’09-model) 18-91 pair (air supply) system diagram pair (air supply) system hose routing page 18-72 *1 *3 *2 1 pair control solenoid valve *1 from air cleaner 2 pair reed valve *2 to #1 cylinder a fresh air *3 to #2 cylinder.

  • Page 632

    18-92 vl800/c/tk9 (’09-model) evap canister hose routing (only for e-33) *1 *3 *4 *3 *4 *6 *7 2 – 5 mm (0.08 – 0.20 in) *4 *2 *5 1 surge hose *2 matching mark (white) 2 fuel shut-off valve *3 the end of the clamp should face right side. 3 surge hose *4 the end of the clamp should face forward. 4 eva...

  • Page 633

    Wiring diagram vl800k5 (’05-model) e-02, 19, 24 wiring diagrams wire color, refer to section “wire color”. O/r p b w o/r p b/w o/r p b w o/r p b/w w b/w b /b b y g b/ g /w b b/w /w w/b b lg b / bl y g /r b g w/ g/ l /g b br b br g b bl b br/w b/ l o/ b /w bl b b /g b br b/w r/bl o/g y/r br y/b w/bl ...

  • Page 634

    Vl800k5 (’05-model) e-03, 28, 33 o r p /w o/r p b/w o/r p b/w o/r p b/w w b w b b b y g b y gr w /b b w w b/lg b /r b / /r b/g w r g y bl /g b r b b /b br w b bl o/y bl w b /b b g b br b w /bl o w y/r br /b r y w g w dg p w b/w br/b b y g b/y gr/w gr/b b/w p/w b/lg bl/r bl/y gr/r b/g w/r g/y bl y/g ...

  • Page 635

    For e-03, 28, 33 y/r b/w b/lg r/b y/r b/w b/lg y/b m fuel pump o/ro r p b/wb/w o/r p b/w o/ro r p b/wb w o/r p b/w w b/wb w br/bbr b b y g b/yb/y gr/wg /w gr/bg / b/wb w w b/lg bl r bl/yb y gr/rg / b g w/rw/r g/yg blbl /g b/br / r g/bg b bl b br/wb /w b/blb/bl o/yo y bl/wb /w bl b bl/gbl g b/brb/br ...

  • Page 636

    Wiring diagram vl800k7 for e-02, 19, 24 m /bb g ll o/ro r b/w /w o/r p b/w o/ro r b/wb/w o/r p b/w w b w r/b b y g /y gr w g /b b/ p w w b /lg l r b /y g /r b/g w r g y bl y/g / r / r g b l b br w b/bl o y l w l b l/g / r b/w /bl o/g y/ r y/ w bl r / g/ dg p w b/w br/b b y g b/y gr/w gr/b b/w p/w w/...

  • Page 637

    For e-03, 28, 33 m y/by b y/gy g w/yw y o g/b b g blbl o/ro r p b/wb w o/r p b/w o/ro r b/wb/w o/r p b/w w b/wb w br/b r/b b y g b/y /y gr/w r/ gr/bg /b b/wb/ p/wp b/lg /lg bl/rb / bl/yb /y gr/rg /r b/g /g w/rw r g/yg y blbl y/gy/g b/br /br g/bg b bl/bb / br/wbr b/blb/ l o/yo y bl/w l w bl/bb / bl/g...

  • Page 638

    Wiring diagram vl800/c/tk9 for e-03, 28 p lock off on off on on off m push free on off on off push free l push r off on hi lo push handlebar switch (r) rear brake switch ignition coil (f-m) ignition coil (f-i) ignition switch engine stop switch front brake switch starter button resistor ecm tp senso...

  • Page 639

    Vl800/c/tk9 for e-33 p lock off on off on on off m push free on off on off push free l push r off on hi lo push handlebar switch (r) rear brake switch ignition coil (f-m) ignition coil (f-i) ignition switch engine stop switch front brake switch starter button ho2 sensor (f) ho2 sensor (r) resistor e...