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- Intruder VL800
- Supplementary Service Manual
Suzuki Intruder VL800 Supplementary Service Manual
Summary of Intruder VL800
Page 1
Printed in japan k5 9 9 5 0 1 - 3 8 0 8 0 - 0 1 e top bottom use this manual with: vl800 service manual (99500-38043-01e).
Page 2: Important
Important all street-legal suzuki motorcycles with engine displacement of 50 cc or greater are subject to environmental protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includ...
Page 3: Vl800K5 (’05-Model)
Contents vl800k5 (’05-model) this manual described the service specifications, service data, fi system and servicing proce- durers which differ from those of the vl800k4 (’04-model). Note: * any differences between the vl800k4 (’04-model) and vl800k5 (’05-model) in specifica- tions and service data ...
Page 4: Specifications
2 vl800k5 (’05-model) specifications dimensions and dry mass overall length ...................................................................................... 2 510 mm (98.8 in) overall width ....................................................................................... 985 mm (38.8 in)...
Page 5: Abbreviations Used In This
Vl800k5 (’05-model) 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/f ...
Page 6
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 : re...
Page 7: Sae-to-Former Suzuki Term
Vl800k5 (’05-model) 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 air...
Page 8
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 pulsed s...
Page 9: Service Data
Vl800k5 (’05-model) 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 – 0...
Page 10
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. 36....
Page 11
Vl800k5 (’05-model) 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 12
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 (at ...
Page 13
Vl800k5 (’05-model) 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 stan...
Page 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 regulator ...
Page 15
Vl800k5 (’05-model) 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 specificat...
Page 16
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 coolant t...
Page 17
Vl800k5 (’05-model) 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 (2....
Page 18
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 ap...
Page 19: Periodic Maintenance Chart
Vl800k5 (’05-model) 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 idle s...
Page 20: Precautions In Servicing
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 type c...
Page 21
Vl800k5 (’05-model) 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 female ...
Page 22
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 re...
Page 23
Vl800k5 (’05-model) 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 as ...
Page 24
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. If n...
Page 25
Vl800k5 (’05-model) 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/coupler...
Page 26
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 th...
Page 27: Fi System Technical Features
Vl800k5 (’05-model) 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. These ...
Page 28
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 tempera...
Page 29
Vl800k5 (’05-model) 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 sa mp le.
Page 30
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 sa mp le.
Page 31
Vl800k5 (’05-model) 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 pump...
Page 32: Self-Diagnosis Function
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, th...
Page 33
Vl800k5 (’05-model) 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. T...
Page 34
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. In ...
Page 35
Vl800k5 (’05-model) 33 tps adjustment 1. Lift and support the fuel tank. ( $page 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 senso...
Page 36: Fail-Safe Function
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 se...
Page 37: Fi System Troubleshooting
Vl800k5 (’05-model) 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 analy...
Page 38
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 ins...
Page 39
Vl800k5 (’05-model) 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 will e...
Page 40
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 malfunction ...
Page 41
Vl800k5 (’05-model) 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 the ...
Page 42
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 is p...
Page 43
Vl800k5 (’05-model) 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. Sa mp le.
Page 44: Ecm Terminal
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 (tp...
Page 45
Vl800k5 (’05-model) 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 part...
Page 46
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 than...
Page 47
Vl800k5 (’05-model) 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 switc...
Page 48
46 vl800k5 (’05-model) “c12” (p0335) ckp sensor circuit malfunction inspection step 1 1) remove the left frame cover. ( $vl800k1 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 measu...
Page 49
Vl800k5 (’05-model) 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: multi-...
Page 50
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 procedure a...
Page 51
Vl800k5 (’05-model) 49 “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction inspection step 1 1) remove the fuel tank. ( $page 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 measur...
Page 52
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 and b...
Page 53
Vl800k5 (’05-model) 51 is the voltage ok? 4) after repairing the trouble, clear the dtc using sds tool. ( $page 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 54
52 vl800k5 (’05-model) “c14” (p0120) tp sensor circuit malfunction inspection step 1 (when indicating c14:) 1) remove the fuel tank. ( $page 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 55
Vl800k5 (’05-model) 53 step 1 (when indicating p0120-h:) 1) remove the fuel tank. ( $page 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 continuity...
Page 56
54 vl800k5 (’05-model) step 1 (when indicating p0120-l:) 1) remove the fuel tank. ( $page 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 continuity...
Page 57
Vl800k5 (’05-model) 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 wire...
Page 58
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 output ...
Page 59
Vl800k5 (’05-model) 57 “c15” (p0115) ect sensor circuit malfunction inspection step 1 (when indicating c15:) 1) remove the fuel tank. ( $page 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 c...
Page 60
58 vl800k5 (’05-model) step 1 (when indicating p0115-h:) 1) remove the fuel tank. ( $page 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) c...
Page 61
Vl800k5 (’05-model) 59 step 1 (when indicating p0115-l:) 1) remove the fuel tank. ( $page 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 continu...
Page 62
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) che...
Page 63
Vl800k5 (’05-model) 61 “c21” (p0110) iat sensor circuit malfunction inspection step 1 (when indicating c21:) 1) remove the air cleaner box. ( $page 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 wire...
Page 64
62 vl800k5 (’05-model) step 1 (when indicating p0110-h:) 1) remove the air cleaner box. ( $page 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 couple...
Page 65
Vl800k5 (’05-model) 63 step 1 (when indicating p0110-l:) 1) remove the air cleaner box. ( $page 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 66
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 sensor...
Page 67
Vl800k5 (’05-model) 65 “c23” (p1651) to sensor circuit malfunction inspection step 1 (when indicating c23:) 1) remove the right frame cover. ( $vl800k1 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) di...
Page 68
66 vl800k5 (’05-model) step 1 (when indicating p1651-h:) 1) remove the right frame cover. ( $vl800k1 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 th...
Page 69
Vl800k5 (’05-model) 67 step 1 (when indicating p1651-l:) 1) remove the right frame cover. ( $vl800k1 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 th...
Page 70
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, measure...
Page 71
Vl800k5 (’05-model) 69 “c28” (p1655) stv actuator circuit malfunction inspection step 1 1) remove the fuel tank. ( $page 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. ( $page 103) 5) turn the ignition switch on to ...
Page 72
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) an...
Page 73
Vl800k5 (’05-model) 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 func...
Page 74
72 vl800k5 (’05-model) “c29” (p1654) stp sensor circuit malfunction inspection step 1 (when indicating c29:) 1) remove the fuel tank. ( $page 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) disconne...
Page 75
Vl800k5 (’05-model) 73 step 1 (when indicating p1654-h:) 1) remove the fuel tank. ( $page 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 continu...
Page 76
74 vl800k5 (’05-model) step 1 (when indicating p1654-l:) 1) remove the fuel tank. ( $page 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 continu...
Page 77
Vl800k5 (’05-model) 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 yell...
Page 78
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 (between ...
Page 79
Vl800k5 (’05-model) 77 is the voltage ok? 6) after repairing the trouble, clear the dtc using sds tool. ( $page 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 wi...
Page 80
78 vl800k5 (’05-model) “c31” (p0705) gp switch circuit malfunction inspection step 1 1) remove the left frame cover. ( $vl800k1 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 switc...
Page 81
Vl800k5 (’05-model) 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 co...
Page 82
80 vl800k5 (’05-model) “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection step 1 1) remove the air intake pipe. ( $page 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 83
Vl800k5 (’05-model) 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-circui...
Page 84
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 or poor contacts. 4) if ok, then check the insulation and continuity. Refer to page 96 for details. ...
Page 85
Vl800k5 (’05-model) 83 “c49” (p1656) pair control solenoid valve circuit malfunction inspection step 1 1) remove the fuel tank. ( $page 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 valv...
Page 86
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 val...
Page 87
Vl800k5 (’05-model) 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 solenoi...
Page 88
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. (vl800k1 7-2) 2) turn the ignition switch off. 3) check the ho2 sensor coupler for loose or poor contacts. If ok, then check...
Page 89
Vl800k5 (’05-model) 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. " 09900-25008...
Page 90
88 vl800k5 (’05-model) step 1 (when indicating c44/p0135:) 1) remove the right frame cover. (vl800k1 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 mea...
Page 91
Vl800k5 (’05-model) 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: * temperatu...
Page 92: Sensors
90 vl800k5 (’05-model) sensors ckp sensor inspection the crankshaft position sensor is installed in the generator cover. ( $page 46) ckp sensor removal and installation • remove the generator cover. ( $vl800k1 3-18) • install the generator cover in the reverse order of removal. Iap sensor inspection...
Page 93
Vl800k5 (’05-model) 91 iat sensor inspection the intake air temperature sensor is installed at the back side of the air cleaner box. ( $page 61) iat sensor removal and installation • remove the air cleaner box. ( $page 103) • remove the iat sensor from the air cleaner box. • install the iat sensor i...
Page 94: Fuel Delivery System
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 an...
Page 95: Fuel System
Vl800k5 (’05-model) 93 fuel system fuel tank lift-up • remove the seat. ( $vl800k1 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 twis...
Page 96
94 vl800k5 (’05-model) fuel pressure inspection • lift and support the fuel tank. ( $page 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 97
Vl800k5 (’05-model) 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 inspection +...
Page 98
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 terminal...
Page 99
Vl800k5 (’05-model) 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 sa mp le.
Page 100
98 vl800k5 (’05-model) fuel pump removal and disassembly • remove the fuel tank. ( $page 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. • sepa...
Page 101
Vl800k5 (’05-model) 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 the...
Page 102
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. Sa mp le.
Page 103
Vl800k5 (’05-model) 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 specif...
Page 104: Throttle Body
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 tp ...
Page 105
Vl800k5 (’05-model) 103 air cleaner box removal • remove the fuel tank. ( $page 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 an...
Page 106
104 vl800k5 (’05-model) throttle body removal • remove the air intake pipe. ( $page 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 thr...
Page 107
Vl800k5 (’05-model) 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 no...
Page 108
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 iden...
Page 109
Vl800k5 (’05-model) 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 cleaning...
Page 110
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 mount...
Page 111
Vl800k5 (’05-model) 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 assemb...
Page 112
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 thr...
Page 113
Vl800k5 (’05-model) 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 sens...
Page 114
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 deta...
Page 115
Vl800k5 (’05-model) 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, depe...
Page 116
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 variation: ...
Page 117
Vl800k5 (’05-model) 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. ( $page 93) • start up the engine and run it in idling condition for warming up. • stop the warmed-up ...
Page 118
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. Not...
Page 119
Vl800k5 (’05-model) 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: the ...
Page 120
118 vl800k5 (’05-model) throttle position sensor (tps) setting after all adjustments are completed, check or adjust the tps 1 setting condition. Sa mp le.
Page 121: Emission Control Systems
Vl800k5 (’05-model) 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 fuel...
Page 122
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 valve...
Page 123
Vl800k5 (’05-model) 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 devi...
Page 124: Inspection
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 fo...
Page 125
Vl800k5 (’05-model) 123 pair control solenoid valve • lift and support the fuel tank. ( $page 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 126: (Only For E-33)
124 vl800k5 (’05-model) evaporative emission control system inspection (only for e-33) • remove the seats 1. ( $vl800k1 7-2) • remove the speedometer 2. ( $vl800k1 5-3) • remove the fuel tank 3. ( $page 93) • remove the fuel frame cover 4. ( $vl800k1 7-2) hoses (evap hose) inspect the hoses for wear...
Page 127: Tightening Torque
Vl800k5 (’05-model) 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 23...
Page 128
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 tu...
Page 129
Vl800k5 (’05-model) 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 sa mp le.
Page 130
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 sa mp le.
Page 131
Vl800k5 (’05-model) 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 cushion...
Page 132
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 and w...
Page 133
Vl800k5 (’05-model) 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. Sa mp le.
Page 134
132 vl800k5 (’05-model) fuel tank installation frame cut the clamp sa mp le.
Page 135
Vl800k5 (’05-model) 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 sa mp le.
Page 136
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. Sa mp le.
Page 137
Vl800k5 (’05-model) 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 co...
Page 138
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. Sa mp le.
Page 139: Special Tools
Vl800k5 (’05-model) 137 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 09...
Page 140
138 vl800k5 (’05-model) 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 light ...
Page 141
Wiring diagram 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 br/b b y g b/y gr/w gr/b b/w p/w w/b b/lg bl/r bl/y gr/r b/g w/r g/y bl y/g b/br b/br g/b bl/b br/w b/bl o/y bl/w bl/b bl/g b/br b/w r/bl o/g y/r br y/b w/bl r y/w g/w...
Page 142
E-03, 28, 33 o/r p b/w o/r p b/w o/r p b/w o/r p b/w 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 b/br g/b bl/b br/w b/bl o/y bl/w bl/b bl/g b/br b/w r/bl o/w y/r br y/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 b/br...
Page 143
Prepared by june, 2004 part no.99501-38080-01e printed in japan 158 sa mp le.
Page 144
Printed in japan k5 9 9 5 0 1 - 3 8 0 8 0 - 0 1 e top bottom use this manual with: vl800 service manual (99500-38043-01e).