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- Intruder VZR1800
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Suzuki Intruder VZR1800 Service Manual
Summary of Intruder VZR1800
Page 1
9 9 5 0 1 - 3 9 5 9 0 - 0 1 e supplementary service manual use this manual with: vzr1800 service manual (99500-39293-01e).
Page 2: Vzr1800/zl0 (’10-Model)
Vzr1800/zl0 (’10-model) 1 contents vzr1800/zl0 (’10-model) © copyright suzuki motor corporation 2010 this manual describes service specifications, service data and servicing procedures which dif- fer from those of the vzr1800/nk9 (’09-model). Note: please refer to the vzr1800/nk9 (’09-model) service...
Page 3: Vzr1800/zl0 (’10-Model)
2 vzr1800/zl0 (’10-model) vzr1800/zl0 (’10-model) contents country and area codes the following codes stand for the applicable country(-ies) and area(-s). Model code country or area effective frame no. Vzr1800 e-02 e-03 e-19 e-19 (uf) e-24 e-28 e-33 e-51 u.K. U.S.A. (except for california) e.U. E.U....
Page 4: Information Labels
Vzr1800/zl0 (’10-model) 3 information labels a: attached vzr1800 vzr1800uf 1 noise label a (for e-03, 24, 33) 2 information label a (for e-03, 28, 33, 51) 3 vacuum hose routing label a (for e-33) 4 fuel information label a a 5 manual notice label a (for e-03, 33) 6 tire information label a a 7 gener...
Page 5: Specifications
4 vzr1800/zl0 (’10-model) specifications note: any differences between the vzr1800/nk9 (’09-model) and vzr1800/zl0 (’10-model) in specifications are indicated with an asterisk mark (*). Dimensions and curb mass overall length.......................................................* 2 450 mm (96.5 in)...
Page 6
Vzr1800/zl0 (’10-model) 5 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or ...
Page 7
6 vzr1800/zl0 (’10-model) engine components inspection and servicing camshaft each exhaust camshaft i.D. Code a has been changed which is stamped on the camshaft end. Cam wear cam height h service limit (ex.): 40.18 mm (1.582 in) \ 09900-20202: micrometer (25 – 50 mm) front cylinder rear cylinder i....
Page 8
Vzr1800/zl0 (’10-model) 7 clutch construction 2.3 mm (0.09 in) 3.4 mm (0.13 in) 2.9 mm (0.11 in) 3.0 mm (0.12 in) 2.0 mm (0.08 in) t a driven plate no. 1 b driven plate no. 2 b drive plate no. 2, 3, 4 a drive plate no. 1 drive plate: drive plate no. 1 ...........6 pcs. Drive plate no. 2 drive plate ...
Page 9
8 vzr1800/zl0 (’10-model) inspection clutch plate thickness note: wipe off engine oil from the clutch plates with a clean rag. • measure the thickness of drive and driven plates with a ver- nier calipers. If each plate is not within the service limit or standard range, replace it with a new one. Dri...
Page 10
Vzr1800/zl0 (’10-model) 9 crankshaft journal bearing selection crankshaft journal oil clearance: standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) service limit: 0.080 mm (0.0031 in) \ 09900-22301: plastigauge (0.025 – 0.076 mm) bearing thickness specification color (part no.) thickness green (12229-4...
Page 11: Driveline/axle
10 vzr1800/zl0 (’10-model) driveline/axle secondary gear shims adjustment adjust backlash and tooth contact by selecting shims. (use two pieces of shims.) shim 1 size table the shims 1 are available as a set (24945-48820). Universal joint installation • apply lithium base molybdenum grease (nlgi#2) ...
Page 12: Fi System
Vzr1800/zl0 (’10-model) 11 fi system fi system parts location a tachometer/gear position b isc valve (iscv) c intake air pressure sensor #2 (iaps) d ignition coil #1 (ig coil) e secondary throttle position sensor (stps) f throttle position sensor (tps) g secondary throttle valve actuator (stva) h pa...
Page 13
12 vzr1800/zl0 (’10-model) a speedometer b intake air temperature sensor (iats) c pair control solenoid valve d fuel injector #1 e fuel injector #2 f intake air pressure sensor #1 (iaps) g fuel pump h ignition coil/plug cap #1 i tip-over sensor (tos) j fuel pump relay (fp relay) k cooling fan relay ...
Page 14: Exhaust System
Vzr1800/zl0 (’10-model) 13 exhaust system construction 23 n·m (2.3 kgf-m, 16.5 lbf-ft) 4.0 mm (0.16 in) and more no. 1 no. 2 58 – 59 mm (2.28 – 2.32 in) 42 – 43 mm (1.65 – 1.69 in) 4.0 mm (0.16 in) and more 8.5 – 9.5 mm (0.33 – 0.73 in) no. 1 no. 2 23 n·m (2.3 kgf-m, 16.5 lbf-ft) 23 n·m (2.3 kgf-m, ...
Page 15: Front Fork
14 vzr1800/zl0 (’10-model) front fork construction " fwd 1 o-ring 6 oil seal stopper ring a front fork cap bolt 2 spacer 7 dust seal b inner rod lock nut 3 outer tube 8 spring c damper rod bolt 4 oil seal retainer 9 inner rod/damper rod (cartridge) d front axle pinch bolt 5 oil seal 0 inner tube ite...
Page 16
Vzr1800/zl0 (’10-model) 15 removal and disassembly • remove the headlight housing assembly. ( page 29) • remove the front wheel. ( vzr1800k6 9-9) • remove the front reflex refractor 1. (for e-03, 28, 33) • remove the bolts, left and right and front fender 2. • loosen the front fork upper clamp bolt ...
Page 17
16 vzr1800/zl0 (’10-model) • remove the front fork cap bolt 4 from the inner rod by loos- ening the lock nut. • remove the special tools. • remove the spacer 6 and spring 7. • remove the front axle pinch bolts. (for rh) • invert the front fork and stroke the inner rod several times to let out fork o...
Page 18
Vzr1800/zl0 (’10-model) 17 • remove the inner rod/damper rod (cartridge) 8. • extract the outer tube from the inner tube. Note: be careful not to damage the “anti-friction” metals. • remove the dust seal 9 and oil seal stopper ring 0. • remove the oil seal with the special tool. \ 09913-50121: oil s...
Page 19
18 vzr1800/zl0 (’10-model) inspection inner and outer tubes • inspect the inner tube outer surface and outer tube inner sur- face for scratches. • inspect the “anti-friction” metal surfaces for scratches. • if any defects are found, replace them with a new one. Fork spring • measure the fork spring ...
Page 20
Vzr1800/zl0 (’10-model) 19 reassembly reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: oil seal and dust seal • install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. 1 dust seal 2 oil seal stopper ring 3...
Page 21
20 vzr1800/zl0 (’10-model) • tighten the damper rod bolt to the specified torque with the special tool. \ 09940-30221: front fork cylinder holder " damper rod bolt: 23 n·m (2.3 kgf-m, 16.5 lbf-ft) fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front ...
Page 22
Vzr1800/zl0 (’10-model) 21 front fork inner rod lock nut • tighten the lock nut 1 to the bottom of inner rod threads. Fork spring • install the fork spring as shown in the illustration. • install the spring 1 and spacer 2. Front fork cap bolt • pull up the inner rod with the special tool a. • compre...
Page 23
22 vzr1800/zl0 (’10-model) installation install the front fork in the reverse order of removal. Pay atten- tion to the following points: • install the front fork to the steering stem and steering stem upper bracket. • install the top of outer tube 5 mm (0.2 in) a higher than the upper surface of the...
Page 24: Steering
Vzr1800/zl0 (’10-model) 23 steering construction " *1 1 handlebar clamp 6 steering stem upper bearing c front fork upper clamp bolt 2 handlebar clamp holder 7 steering stem lower bearing d handlebar holder bolt 3 steering stem upper bracket 8 steering stem e front fork lower clamp bolt 4 steering st...
Page 25: Charging System
24 vzr1800/zl0 (’10-model) rear brake caliper and bracket installation • apply thread lock super to the brake caliper bracket mounting bolt 1 and tighten its to the specified torque. • apply thread lock super to the rear brake caliper mounting bolts 2 and tighten them to the specified torque. G 9900...
Page 26: Speedometer and Tachometer
Vzr1800/zl0 (’10-model) 25 speedometer and tachometer description this speedometer and tachometer mainly consists of the stepping motor (except for tachometer), lcd (liq- uid crystal display) and led (light emitting diode). The speedometer pointer is driven by the stepping motor. The lcds indicate t...
Page 27
26 vzr1800/zl0 (’10-model) tachometer removal and disassembly • remove the headlight housing assembly. ( page 30) • remove the headlight upper cover. ( page 30) • remove the tachometer 1. • disassemble the tachometer as follows. ☆ : hooked part do not attempt to disassemble the tachometer unit 2. Fw...
Page 28
Vzr1800/zl0 (’10-model) 27 engine coolant temperature meter and indicator inspection ect sensor inspection ( vzr1800k68-9) • remove the right frame side cover. ( vzr1800k69-5) • remove the right air cleaner box. ( vzr1800k66-13) • disconnect the ect sensor coupler 1. • connect the speedometer couple...
Page 29
28 vzr1800/zl0 (’10-model) fuel level meter inspection • lift and support the fuel tank. ( vzr1800k66-3) • disconnect the fuel pump lead wire coupler 1. • connect variable resistor between the r/b and b/w lead wires at the wire harness. • turn the ignition switch “on” position and wait for approx. 4...
Page 30: Headlight Housing/tachome-
Vzr1800/zl0 (’10-model) 29 headlight housing/tachome- ter and headlight cover brace removal • remove the bolts 1. ☆ : hooked part • disconnect the headlight coupler 2 and tachometer couplers 3. • remove the headlight housing assembly 4. • remove the headlight upper cover 5. ☆ : hooked part • remove ...
Page 31
30 vzr1800/zl0 (’10-model) • disconnect the front turn signal light couplers 0. • remove the front turn signal lights b by removing the mounting screws a. • remove the front turn signal light cover bolt c. • remove the front turn signal cover e by removing the cover bolts d. • disconnect the throttl...
Page 32: Battery Ground Wire
Vzr1800/zl0 (’10-model) 31 battery ground wire installation the battery ground wire fixing point was changed. Clamp battery ground wire lower crankcase.
Page 33: Tightening Torque
32 vzr1800/zl0 (’10-model) tightening torque engine driveline/axle chassis service data note: any differences between the vzr1800/nk9 (’09-model) and vzr1800/zl0 (’10-model) in service data are indicated with an asterisk mark (*) and highlighting (halftone screen). Camshaft + cylinder head unit: mm ...
Page 34
Vzr1800/zl0 (’10-model) 33 cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure (automatic de-comp. Actuated) * 900 – 1 800 kpa (9.0 – 18.0 kgf/cm 2 , 128 – 256 psi) 800 kpa (8.0 kgf/cm 2 , 114 psi) compression pressure difference — 200 kpa (2.0 kgf/cm 2 , 28 psi) p...
Page 35
34 vzr1800/zl0 (’10-model) conrod + crankshaft unit: mm (in) clutch unit: mm (in) item standard limit conrod small end i.D. 23.010 – 23.018 (0.9059 – 0.9062) 23.040 (0.9071) conrod big end side clearance 0.100 – 0.200 (0.0039 – 0.0078) 0.30 (0.012) conrod big end width 23.95 – 24.00 (0.943 – 0.945) ...
Page 36: Wiring Diagram
Vzr1800/zl0 (’10-model) 35 suspension unit: mm (in) wiring diagram item standard limit front fork stroke 130 (5.1) — front fork spring free length * 390 (15.4) * 382 (15.0) front fork inner tube o.D. 46 (1.8) — front fork oil level (without spring, inner tube fully compressed) * 115 (4.5) — front fo...
Page 37: Wiring Harness Routing
36 vzr1800/zl0 (’10-model) wiring harness routing clamp clamp wiring harness clamp isc valve wiring harness face the lead wire to the lower. Set the speedometer harness to the right side. Do not pinch the wiring harness between fuel tank and frame. Clamp wiring harness clamp to o2 sensor clamp clamp...
Page 38
Vzr1800/zl0 (’10-model) 37 clamp ignition coil high tension cord wiring harness pass the wiring harness over the breather hose. Pass the lead wire outside of the terminal. Pass the ignition coil/plug cap lead wire over the breather hose. Horn clamp pass the starter motor lead wire inside of the rear...
Page 39: Cable Routing
38 vzr1800/zl0 (’10-model) cable routing pass the throttle cables behind the right handlebar switch lead wire, brake switch lead wire and brake hose. Throttle cable clip 250 mm (9.8 in) throttle cable no.1 throttle cable no.2 cable guide no.2 headlight cover brace clutch cable cable guide no.2 throt...
Page 40: Front Brake Hose Routing
Vzr1800/zl0 (’10-model) 39 front brake hose routing 14 14 * 1 * 3 * 2 * 5 * 3 * 4 * 1 * 4 * 3 * 1 1 front brake hose * 2 tighten the bolt after positioning the brake hose joint to the stopper of headlight cover brace. 2 front brake caliper (r) 3 front brake caliper (l) * 3 fix the brake hose to the ...
Page 41: Rear Brake Hose Routing
40 vzr1800/zl0 (’10-model) rear brake hose routing 1 stopper * 2 clamp ends should face upward. 2 reservoir tank * 3 insert the reservoir hose fully to the reservoir tank and brake master cylinder. 3 brake master cylinder * 4 face the white paint on reservoir hose to forward. 4 brake hose * 5 tighte...
Page 42: Cooling System Hose Routing
Vzr1800/zl0 (’10-model) 41 cooling system hose routing radiator cap radiator mark inside. White mark red mark thermostat face the tip of clip to the inside. Yellow mark red mark oil cooler red mark reservoir inlet hose reservoir overflow hose red mark white mark white mark red mark yellow mark white...
Page 43: Fuel Tank Installation
42 vzr1800/zl0 (’10-model) fuel tank installation 1 heat shield 6 fuel tank cushion 2 fuel pump 7 rear fender cover cushion 3 clamp 8 apply instant adhesive to the shaded portion. 4 adhere the heat shield on the tank with the dou- ble-faced tape. 9 fuel tank rear bracket 5 face the arrow mark to the...
Page 44
Vzr1800/zl0 (’10-model) 43 left frame covers installation 1 rear fender 5 lower side cover 2 rear fender cover 6 cushion 3 rear side cover 7 10 ± 2 mm (0.4 ± 0.1 in) 4 side cover 8 0 ± 1 mm (0 ± 0.04 in).
Page 45
44 vzr1800/zl0 (’10-model) right frame covers installation 1 rear fender 5 lower cover 2 rear fender cover 6 cushion 3 rear side cover 7 15 ± 2 mm (0.6 ± 0.1 in) 4 side cover 8 0 ± 1 mm (0 ± 0.04 in).
Page 46: Headlight Cover Installation
Vzr1800/zl0 (’10-model) 45 headlight cover installation 1 headlight lower cover 5 headlight housing bracket cover * 1 to headlight 2 headlight housing brace 6 headlight cover brace * 2 to front cover 3 headlight cover 7 steering stem upper bracket 4 headlight upper cover 8 steering stem lower bracke...
Page 47
46 vzr1800/zl0 (’10-model) front turn signal light installation 1 front turn signal cover 8 headlight housing bracket cover 2 front turn signal light (r) 9 position light coupler (r) [for e-03, 28, 33] 3 front turn signal light (l) 0 front turn signal coupler (r) 4 front turn signal light mounting s...
Page 48
Vzr1800/zl0 (’10-model) 47 secondary gear case cover damper installation rear fender cushion installation 1 secondary gear case cover 4 secondary gear case cover damper 2 engine oil note 5 5 – 10 mm (0.2 – 0.4 in) 3 secondary gear case cover damper 6 5 – 7 mm (0.2 – 0.3 in) 1 rear fender 4 cushion 2...
Page 49
Prepared by january, 2010 part no. 99501-39590-01e printed in japan 48.
Page 50
Printed in japan l0