Suzuki VL1500K5 Supplementary Service Manual
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Suzuki VL1500K5 Supplementary Service Manual

Suzuki VL1500K5 Supplementary Service Manual

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USE THIS MANUAL WITH:
VL1500 SERVICE MANUAL (99500-39166-01E)

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Summary of Contents for Suzuki VL1500K5

  • Page 1 VL1500 USE THIS MANUAL WITH: VL1500 SERVICE MANUAL (99500-39166-01E)

  • Page 2: Table Of Contents

    VL1500K4 (’04-model). NOTE: • Any differences between the VL1500K4 (’04-model) and VL1500K5 (’05-model) in specifications and service data are indicated with an asterisk mark (*). • Please refer to the VL1500 service manual for details which are not given this manual.

  • Page 3: Country And Area Codes

    VL1500K5 (’05-MODEL) SWITCHES......................142 BATTERY......................143 WIRING HARNESS, CABLE AND HOSE ROUTING........144 EXTERIOR PARTS INSTALLATION..............153 SPECIAL TOOLS....................157 TIGHTENING TORQUE ..................158 SERVICE DATA ....................159 EMISSION CONTROL SYSTEMS ..............168 PAIR (AIR SUPPLY) SYSTEM INSPECTION ..........172 PAIR (AIR SUPPLY) SYSTEM DIAGRAM ............

  • Page 4: Abbreviations Used In This Manual

    VL1500K5 (’05-MODEL) ABBREVIATIONS USED IN THIS MANUAL : Engine Control Module ABDC : After Bottom Dead Center Engine Control Unit (ECU) : Alternating Current (FI Control Unit) : Air Cleaner, Air Cleaner Box EOT Sensor : Engine Oil Temperature : American Petroleum Institute Sensor (EOTS), Oil Temp.
  • Page 5 VL1500K5 (’05-MODEL) MAL-Code : Malfunction Code (Diagnostic Code) : Maximum : Malfunction Indicator Lamp (LED) : Minimum : Nitrogen Oxides : Over Head Camshaft : Oil Pressure Switch PAIR : Pulsed Secondary Air Injection : Positive Crankcase Ventilation (Crankcase Breather)

  • Page 6: Specifications

    VL1500K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 525 mm (99.4 in) Overall width............* 995 mm (40.2 in) ....E-24 Overall width............* 1 020 mm (40.2 in) ....Others Overall height ............* 1 125 mm (44.3 in) Wheelbase ............
  • Page 7 VL1500K5 (’05-MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........140 mm (5.5 in) Rear wheel travel ..........118 mm (4.6 in) Caster ..............32° Trail ..............138 mm (5.43 in) Steering angle............

  • Page 8: Periodic Maintenance Schedule

    VL1500K5 (’05-MODEL) 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 time for your convenience.

  • Page 9: Maintenance And Tune-Up Procedures

    VL1500K5 (’05-MODEL) MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the VL1500K4 (’04-MODEL). For details other than the following items, refer to the VL1500 Service Manual.

  • Page 10: Throttle Cable Play

    VL1500K5 (’05-MODEL) Lock-nut THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. Adjust the throttle cable play A with the following three steps. MINOR ADJUSTMENT First step: •...

  • Page 11: Throttle Valve Synchronization

    VL1500K5 (’05-MODEL) MAJOR ADJUSTMENT • Remove the air cleaner box. (!Page 103) • Loosen the lock-nut 1 of the throttle returning cable. • Turn the returning cable adjuster 2 to obtain proper cable play. • Loosen the lock-nut 3 of the throttle pulling cable.

  • Page 12: Exhaust Pipe Bolts And Muffler Bolts

    VL1500K5 (’05-MODEL) EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.

  • Page 13: Chassis Bolts And Nuts

    VL1500K5 (’05-MODEL) CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to VL1500 Service Manual 2-18 for the locations of the following nuts and bolts.)

  • Page 14: Engine Components Removable With Engine In Place

    VL1500K5 (’05-MODEL) 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 each section for removal and reinstallation instructions. ENGINE LEFT SIDE...

  • Page 15: Engine Removal And Installation

    VL1500K5 (’05-MODEL) ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL The engine removal procedure is different from that of the VL1500K4 (’04-MODEL). For details other than the removal pro- cedure, refer to the VL1500 Service Manual. • Remove the seats. (!Page 121) •...
  • Page 16 VL1500K5 (’05-MODEL) • Remove the PAIR device bracket 7. • Remove the No. 1 and No. 2 PAIR pipes. • Remove the air cleaner box. (!Page 103) • Remove the throttle body. (!Page 104)

  • Page 17: Engine Installation

    VL1500K5 (’05-MODEL) ENGINE INSTALLATION Installation is in the reverse order of removal procedure. • Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque. Apply PERMATEX 1372. Apply PERMATEX 1372. Replace the gaskets with the new ones.

  • Page 18: Engine Disassembly And Reassembly

    • Remove the gear position switch 1. GEAR POSITION SWITCH REASSEMBLY • Apply SUZUKI SUPER GREASE “A” to the O-ring. • When installing the gear position switch 1, align the pin A with the hole B in the gearshift cam retainer 2.

  • Page 19: Engine Components Inspection And Servicing

    VL1500K5 (’05-MODEL) ENGINE COMPONENTS INSPECTION AND SERVICING CAMSHAFT For details other than the following, refer to the VL1500 Service Manual. Each camshaft I.D. code has been changed which is stamped on the camshaft end. I.D. Front cylinder Rear cylinder I.D. code...

  • Page 20: Precautions In Servicing

    VL1500K5 (’05-MODEL) PRECAUTIONS IN SERVICING When handling the FI component parts or servicing the FI sys- tem, observe the following points for the safety of the system. CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt.
  • Page 21 VL1500K5 (’05-MODEL) • 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.
  • Page 22 VL1500K5 (’05-MODEL) Ignition S/W • When disconnecting and connecting the ECM couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. INCORRECT Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

  • Page 23: Electrical Circuit Inspection Procedure

    VL1500K5 (’05-MODEL) 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 circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
  • Page 24 VL1500K5 (’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. • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 25 VL1500K5 (’05-MODEL) SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. To other • Disconnect the connectors/couplers at both ends of the circuit parts to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 26 VL1500K5 (’05-MODEL) USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER MULTI-CIRCUIT TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.

  • Page 27: Fi System Technical Features

    VL1500K5 (’05-MODEL) 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 the intake air pressure, engine speed and throttle opening angle, and various compensations.

  • Page 28: Injection Stop Control

    VL1500K5 (’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). SIGNAL DESCRIPTION ENGINE OIL TEMPERATURE SENSOR When engine oil temperature is low, injection time (volume) SIGNAL is increased.

  • Page 29: Fuel Delivery System

    VL1500K5 (’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 and pressurized fuel flows into the injector installed in the fuel delivery pipe.

  • Page 30: Fi System Parts Location

    VL1500K5 (’05-MODEL) FI SYSTEM PARTS LOCATION A Speedometer H Gear position switch B Starter relay I HO2 sensor (HO2S) [For E-02, 19, 24] C Starter motor J Crankshaft position sensor (CKPS) D Intake air pressure sensor #1 (IAPS) K Fuel injector #2 (FI)
  • Page 31 VL1500K5 (’05-MODEL) N Intake air pressure sensor #2 (IAPS) S Decompression solenoid O Secondary throttle position sensor (STPS) T Intake air temperature sensor (IATS) P Throttle position sensor (TPS) U Ignition coil #2 (IG COIL) Q Secondary throttle valve actuator (STVA)

  • Page 32: Fi System Wiring Diagram

    VL1500K5 (’05-MODEL) FI SYSTEM WIRING DIAGRAM...

  • Page 33: Ecm Terminal

    VL1500K5 (’05-MODEL) ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) Ignition switch signal (AT) IAT sensor signal (IAT) EOT sensor signal (EOT) Rear cylinder IAP sensor signal (IAP. R) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Blank Front cylinder IAP sensor signal (IAP.

  • Page 34: Self-Diagnosis Function

    VL1500K5 (’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, the dealer mode is prepared.

  • Page 35: Dealer Mode

    VL1500K5 (’05-MODEL) 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 the LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
  • Page 36 VL1500K5 (’05-MODEL) CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor #2 (IAPS #2) For Front cylinder Throttle position sensor (TPS) Engine oil temp. sensor (EOTS) Intake air pressure sensor #1 (IAPS #1) For Rear cylinder Decomp.

  • Page 37: Tps Adjustment

    VL1500K5 (’05-MODEL) TPS ADJUSTMENT 1. Warm up the engine and adjust the engine idle speed to 1 000 ± 100 r/min. (!Page 8) 2. Connect the special tool (Mode select switch) and select the dealer mode. 3. Remove the right frame upper cover.

  • Page 38: Fail-Safe Function

    VL1500K5 (’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. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to “YES”...

  • Page 39: Fi System Troubleshooting

    VL1500K5 (’05-MODEL) 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 analysis and diagnosis.

  • Page 40: Visual Inspection

    VL1500K5 (’05-MODEL) MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C/ °F) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway...
  • Page 41 VL1500K5 (’05-MODEL) SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from the ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diag- nostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

  • Page 42: Use Of Sds Diagnostic Procedures

    VL1500K5 (’05-MODEL) USE OF SDS DIAGNOSTIC PROCEDURES * 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 memory. Such disconnection will erase the memorized information in ECM memory.
  • Page 43 VL1500K5 (’05-MODEL) 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.

  • Page 44: Show Data When Trouble

    VL1500K5 (’05-MODEL) SHOW DATA WHEN TROUBLE (DISPLAING 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”.

  • Page 45: Malfunction Code And Defective Condition

    VL1500K5 (’05-MODEL) MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 3 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts.
  • Page 46 VL1500K5 (’05-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM IAT sensor The sensor voltage should be the fol- IAT sensor, lead wire/coupler lowing. connection. 0.1 V sensor voltage < 4.6 V In other than the above range, C21 (P0110) is indicated.
  • Page 47 VL1500K5 (’05-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Gear posi- Gear position signal voltage should be GP switch, lead wire/coupler tion signal higher than the following for 3 seconds connection, gearshift cam, etc. and more. Gear position sensor voltage > 0.6 V...
  • Page 48 VL1500K5 (’05-MODEL) “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec. or more, • Metal particles or foreign material being stuck on after receiving the starter signal. the CKP sensor and rotor tip.
  • Page 49 VL1500K5 (’05-MODEL) 7) If OK, then check the continuity between each terminal and ground. " CKP sensor continuity: ∞ Ω (Infinity) (Blue – Ground) (Green – Ground) # 09900-25008: Multi-circuit tester set ) Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
  • Page 50 VL1500K5 (’05-MODEL) “C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high • Clogged vacuum passage between throttle body and IAP sensor. (0.1 V Sensor voltage < 4.8 V) • Air being drawn from vacuum passage between NOTE: throttle body and IAP sensor.
  • Page 51 VL1500K5 (’05-MODEL) Is the voltage OK? Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal 6 or D). • Open or short circuit in the Red wire or B/Br wire. 8) After repairing the trouble, clear the DTC using SDS tool.
  • Page 52 VL1500K5 (’05-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (!Page 118) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...
  • Page 53 VL1500K5 (’05-MODEL) Output voltage (Vcc voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg)     3.4 – 4.0 2 000 2 001 ...
  • Page 54 VL1500K5 (’05-MODEL) “C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle open- • TP sensor malfunction.
  • Page 55 VL1500K5 (’05-MODEL) Step 1 (When indicating P0120-H:) 1) Remove the right frame upper cover. (!VL1500 Service Manual 6-3) 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.
  • Page 56 VL1500K5 (’05-MODEL) Step 1 (When indicating P0120-L:) 1) Remove the right frame upper cover. (!VL1500 Service Manual 6-3) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then measure the TP sensor lead wire continuity.
  • Page 57 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Install the test harness to the TP sensor. 4) Check the continuity between terminal A and ground. " TP sensor continuity: ∞ Ω (Infinity) (Terminal A –...
  • Page 58 VL1500K5 (’05-MODEL) Step 3 1) Connect the TP sensor coupler 1 to the test harness. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage at the coupler (between + BI/B and - B/Br) by turning the throttle grip.
  • Page 59 VL1500K5 (’05-MODEL) “C15” (P0115-H/L) EOT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • EOT sensor circuit open or short. range. • EOT sensor malfunction. Sensor voltage < 4.6 V • ECM malfunction. P0115 Sensor voltage is higher than specified •...
  • Page 60 VL1500K5 (’05-MODEL) Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Check the EOT sensor coupler for loose or poor contacts. If OK, then check the EOT sensor lead wire continuity. 3) Remove the left frame upper cover.
  • Page 61 VL1500K5 (’05-MODEL) Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Check the EOT sensor coupler for loose or poor contacts. If OK, then check the EOT sensor lead wire continuity. 3) Disconnect the EOT sensor coupler.
  • Page 62 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the EOT sensor coupler. 3) Measure the EOT sensor resistance. " EOT sensor resistance: Approx. 61.3 kΩ at 20 °C (68 °F) (White – White) # 09900-25008: Multi-circuit tester set ) Tester knob indication: Resistance (Ω)
  • Page 63 VL1500K5 (’05-MODEL) EOT SENSOR INSPECTION • Remove the EOT sensor. (!Page 119) • Check the EOT sensor by testing it at the bench as shown in the figure. Connect the EOT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.
  • Page 64 VL1500K5 (’05-MODEL) “C18” (P1751) DECOMP. RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Decomp. relay signal is not input to ECM. • Decomp. system circuit open or short. • ECM malfunction. Engine stop Side-stand Ignition Decomp. relay switch relay switch To GP switch Decomp.
  • Page 65 VL1500K5 (’05-MODEL) 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 “Decomp sol operating control” 1. 4) With the engine starter button pushed, click “On” button 2.
  • Page 66 VL1500K5 (’05-MODEL) “C19” (P0615) STARTER RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Starter relay signal is not input to ECM. • Starter system circuit open or short. • ECM malfunction. STARTER Engine stop Side-stand Ignition RELAY switch relay switch STRL...
  • Page 67 VL1500K5 (’05-MODEL) “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. Sensor voltage < 4.6 V • ECM malfunction. P0110 Sensor voltage is higher than specified •...
  • Page 68 VL1500K5 (’05-MODEL) Step 1 (When indicating P0110-H:) 1) Remove the right frame upper cover. (!VL1500 Service Manual 6-3) 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.
  • Page 69 VL1500K5 (’05-MODEL) Step 1 (When indicating P0110-L:) 1) Remove the right frame upper cover. (!VL1500 Service Manual 6-3) 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.
  • Page 70 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. " IAT sensor resistance: Approx. 2.45 kΩ at 20 °C (68 °F) (Terminal – Terminal) # 09900-25008: Multi-circuit tester set ) Tester knob indication: Resistance (Ω)
  • Page 71 VL1500K5 (’05-MODEL) “C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short. ing for 2 sec. and more, after ignition • TO sensor malfunction. switch is turned ON.
  • Page 72 VL1500K5 (’05-MODEL) step 1 (When indicating P1651-H:) 1) Remove the seats. (!Page 121) 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.
  • Page 73 VL1500K5 (’05-MODEL) Step 1 (When indicating P1651-L:) 1) Remove the seats. (!Page 121) 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.
  • Page 74 VL1500K5 (’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 Black and B/Br wires.
  • Page 75 VL1500K5 (’05-MODEL) “C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA. • STVA malfunction. ECM does not receive communication signal from • STVA circuit open or short. the STVA. • STVA motor malfunction.
  • Page 76 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each terminal and ground. " STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between Black wire A and Pink wire B) and (between Green wire C and W/ B wire D).
  • Page 77 VL1500K5 (’05-MODEL) 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 the STVA,...
  • Page 78 VL1500K5 (’05-MODEL) “C29” (P1654-H/L) STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Signal voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle open- • STP sensor malfunction.
  • Page 79 VL1500K5 (’05-MODEL) Step 1 (When indicating P1654-H:) 1) Remove the air cleaner box. (!Page 103) 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.
  • Page 80 VL1500K5 (’05-MODEL) Step 1 (When indicating P1654-L:) 1) Remove the air cleaner box. (!Page 103) 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.
  • Page 81 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Remove the air cleaner box. (!Page 103) 3) Disconnect the STP sensor coupler. 4) Check the continuity between each terminal and ground. " STP sensor continuity: ∞ Ω (Infinity) (Terminal –...
  • Page 82 VL1500K5 (’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.
  • Page 83 VL1500K5 (’05-MODEL) “C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage. • Gear Position switch circuit open or short. Switch voltage is not within the following range. • Gear Position switch malfunction. Switch voltage > 0.6 V •...
  • Page 84 VL1500K5 (’05-MODEL) Is the voltage OK? ECM coupler (Harness side) • Red or R/B wire open or shorted to ground. • If wire and connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
  • Page 85 VL1500K5 (’05-MODEL) “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by 4 times or more. • Injector malfunction. • ECM malfunction.
  • Page 86 VL1500K5 (’05-MODEL) 5) 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? Go to Step 2.
  • Page 87 VL1500K5 (’05-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although fuel • Fuel pump relay circuit open or short. pump relay is turned ON, or voltage is applied to fuel •...
  • Page 88 VL1500K5 (’05-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24) DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and •...
  • Page 89 VL1500K5 (’05-MODEL) 7) Remove the left frame upper cover. (!VL1500 Service Manual 6-3) and disconnect the ECM coupler. 8) Check the continuity between W/G wire A and terminal 7. 9) Also, check the continuity between B/Br wire B and terminal D.
  • Page 90 VL1500K5 (’05-MODEL) Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to ground, or poor 7 or D connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM.
  • Page 91 VL1500K5 (’05-MODEL) Step 2 (When indicating C44/P0135:) 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/B wire and ground.
  • Page 92 VL1500K5 (’05-MODEL) “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR valve circuit open or short. ECM. • PAIR valve malfunction. • ECM malfunction. Engine stop...
  • Page 93 VL1500K5 (’05-MODEL) Step 2 1) Turn the ignition switch ON. 2) Measure the voltage between O/W wire and ground. " PAIR valve voltage: Battery voltage (+ O/W – - Ground) # 09900-25008: Multi-circuit tester set * Tester knob indication: Voltage (+)

  • Page 94: Fuel System

    VL1500K5 (’05-MODEL) FUEL SYSTEM FUEL TANK REMOVAL • Remove the seats 1. (!Page 121) • Remove the speedometer and fuel inlet cover 2. (!VL1500 Service Manual 6-3) • Remove the frame head covers 3 and frame upper covers 4. (!VL1500 Service Manual 6-3) •...

  • Page 95: Fuel Pressure Inspection

    VL1500K5 (’05-MODEL) FUEL PRESSURE INSPECTION • Remove the seats. (!Page 121) • Remove the speedometer and fuel inlet cover. (!VL1500 Service Manual 6-3) • Remove the left frame head cover and left frame upper cover. (!VL1500 Service Manual 6-3) • Place a rag under the fuel feed hose.

  • Page 96: Fuel Pump Inspection

    VL1500K5 (’05-MODEL) FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump operates for few seconds. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor.

  • Page 97: Fuel Pump Relay Inspection

    VL1500K5 (’05-MODEL) • Connect a proper lead wire into the fuel pump lead wire cou- pler (fuel pump side) and apply 12 volts to the fuel pump (between Y/R wire and B/W wire) for 10 seconds and mea- sure the amount of fuel discharged.
  • Page 98 VL1500K5 (’05-MODEL) • Remove the fuel feed hose 5. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Disconnect the fuel pump coupler 6. • Remove the fuel pump mounting bolts diagonally. • Lift up the rear part A and turn the fuel pump mounting plate counterclockwise to approx.
  • Page 99 VL1500K5 (’05-MODEL) • Pull the fuel pump mounting plate until the fuel filter 8 comes out from the fuel tank. • Set the fuel pump mounting plate to the horizontal line. • Turn the fuel pump mounting plate counterclockwise to approx.

  • Page 100: Fuel Pump Disassembly

    VL1500K5 (’05-MODEL) FUEL PUMP DISASSEMBLY CONSTRUCTION & 1 Band 4 Fuel pump holder 2 Fuel pump 5 O-ring ITEM N·m kgf-m lb-ft 3 Rubber cushion A Fuel pump mounting bolt...

  • Page 101: Fuel Mesh Filter Inspection And Cleaning

    VL1500K5 (’05-MODEL) DISASSEMBLY • Remove the fuel pump holder 1. • Disconnect the fuel pump coupler 2. • Remove the band 3, rubber cushion 4 and fuel pump 5. 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.
  • Page 102 • Install the new O-ring and apply grease to it. The O-ring must be replaced with a new one to prevent fuel leakage. ( 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) • Install the fuel pump assembly.

  • Page 103: Throttle Body

    VL1500K5 (’05-MODEL) THROTTLE BODY CONSTRUCTION 1 STP sensor 9 Fast idle screw 2 TP sensor 0 IAP sensor & 3 Fuel delivery pipe A STP sensor mounting screw 4 Fuel delivery pipe joint hose B TP sensor mounting screw ITEM N·m kgf-m lb-ft...

  • Page 104: Air Cleaner Box Removal

    VL1500K5 (’05-MODEL) AIR CLEANER BOX REMOVAL • Remove the seats 1. (!Page 121) • Remove the speedometer and fuel inlet cover 2, frame head covers 3, and frame upper covers 4. (!VL1500 Service Manual 6-3) • Loosen the throttle body clamp screws.

  • Page 105: Throttle Body Removal

    VL1500K5 (’05-MODEL) THROTTLE BODY REMOVAL • Remove the air cleaner box. (!Page 103) • Disconnect the throttle cables from their drum. After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.

  • Page 106: Throttle Body Disassembly

    VL1500K5 (’05-MODEL) • Disconnect the TP sensor coupler 4 and IAP sensor vacuum hoses 5. • Remove the throttle body assembly. THROTTLE BODY DISASSEMBLY • Remove the fuel delivery pipe joint hose 1. • Remove the fuel delivery pipes 2...
  • Page 107 VL1500K5 (’05-MODEL) • Remove the TP sensor 3 and STP sensor 4 with the special tool. # 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. Never remove the STVA 5 from the throttle body.

  • Page 108: Throttle Body Cleaning

    VL1500K5 (’05-MODEL) THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

  • Page 109: Throttle Body Reassembly

    * Apply thin coat of the engine oil to the new O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary.
  • Page 110 VL1500K5 (’05-MODEL) • Apply thin coat of the engine oil to the new fuel injector cush- ion seal 3, and install it to the fuel injector. Replace the cushion seal and O-ring with the new ones. • Install the O-ring 4 to the fuel injector.

  • Page 111: Throttle Body Installation

    VL1500K5 (’05-MODEL) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the throttle pulling cable 1 and throttle returning cable 2 to the throttle cable drum. • Loosen each throttle cable lock-nut.

  • Page 112: Fuel Injector Removal

    VL1500K5 (’05-MODEL) • If the STP sensor resistance is out of specification, loosen the STP sensor mounting screw and adjust the STP sensor resis- tance to specification. • Tighten the STP sensor mounting screw. # 09930-11950: Torx wrench & STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.5 lb-ft)

  • Page 113: Fast Idle

    VL1500K5 (’05-MODEL) 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.
  • Page 114 VL1500K5 (’05-MODEL) • Turn the ignition switch ON. • Open the secondary throttle valve fully by turning it with your finger. • With the secondary throttle valve held at this position, mea- sure the output voltage of the TP sensor as shown.
  • Page 115 VL1500K5 (’05-MODEL) THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders. USE OF DIGITAL VACUUM TESTER Step 1 • Remove the seats. (!Page 121) • Remove the speedometer and fuel inlet cover, frame head covers and upper frame covers.
  • Page 116 VL1500K5 (’05-MODEL) NOTE: During balancing the throttle valves, always set the engine rpm at 1 000 r/min, using throttle stop screw. Step 3 • Turn in all the idle air screws to the complete close position. • Check for difference of vacuum between No. 1 and No. 2.
  • Page 117 VL1500K5 (’05-MODEL) • Connect one of the vacuum balancer gauge hose 2 to the vacuum nipple on the No. 1 throttle body. # 09913-13121: Vacuum balancer gauge • Connect a tachometer. • Start up the engine and keep it running at 1 000 r/min by turn- ing throttle stop screw 3.
  • Page 118 VL1500K5 (’05-MODEL) Throttle valve synchronization Using the vacuum balancer gauge, inspect the throttle valve synchronization in the same manner as the digital vacuum tester. Pay attention to the following points: 45 ˚ The vacuum gauge is positioned approx. 45° from the horizontal level, and in this position the two balls should be within one ball dia.

  • Page 119: Sensors

    VL1500K5 (’05-MODEL) SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the rear side of the air cleaner box. (!Page 49) IAP SENSOR REMOVAL/INSTALLATION • Remove the frame head covers and frame upper covers. (!VL1500%Service Manual 6-3) •...

  • Page 120: Ckp Sensor Inspection

    VL1500K5 (’05-MODEL) CKP SENSOR INSPECTION The signal rotor is mounted on the generator rotor and crank- shaft position sensor is installed at the inside of the generator cover. (!VL1500%Service Manual 3-16) CKP SENSOR REMOVAL/INSTALLATION (!VL1500%Service Manual 3D-4) IAT SENSOR INSPECTION The intake air temperature sensor is installed at the front right side of the air cleaner box.

  • Page 121: To Sensor Inspection

    VL1500K5 (’05-MODEL) TO SENSOR INSPECTION The tip-over sensor is located under the front seat. (!Page 70) TO SENSOR REMOVAL/INSTALLATION • Remove the seats. (!Page 121) • Disconnect the coupler 1 and remove the TO sensor. • Installation is in the reverse order of removal.

  • Page 122: Exterior Parts

    VL1500K5 (’05-MODEL) EXTERIOR PARTS SEAT REMOVAL This section gives only exterior parts removal procedure which differ from that of the VL1500K4 (’04-MODEL). For details refer to the chapter 6 of Service Manual. • Remove the rear seat 1. Be careful not to scratch the rear fender.

  • Page 123: Front Fork

    VL1500K5 (’05-MODEL) FRONT FORK CONSTRUCTION 1 O-ring B Oil lock piece 2 Front fork spring C Inner tube cover guide 3 Damper rod ring D Outer tube 4 Rebound Spring E Upper inner tube cover 5 Damper rod F Rubber...

  • Page 124: Removal And Disassembly

    VL1500K5 (’05-MODEL) REMOVAL AND DISASSEMBLY The front fork removal and disassembly procedures are different from those of the VL1500K4 (’04-MODEL). For details other than the following, refer to the VL1500 Service Manual. • Remove the front wheel, front fender and front brake calipers.
  • Page 125 VL1500K5 (’05-MODEL) • Remove the front fork cap bolts 7. INSPECTION For details other than the following, refer to the VL1500 Service Manual. FORK SPRING " Front fork spring free length Service Limit: 589 mm (23.2 in) REASSEMBLY AND REMOUNTING The front fork reassembly and remounting procedures are differ- ent from those of the VL1500K4 (’04-MODEL).
  • Page 126 VL1500K5 (’05-MODEL) • Install the front fork cap bolt. • Install the inner tube cover stopper 1 at 284.3 mm (11.19 in) A from the upper surface of the inner tube. • Set the washer 2 and rubber 3 to the inner tube.
  • Page 127 VL1500K5 (’05-MODEL) • When installing the front fork assembly, align the upper sur- face D of the inner tube with the surface E of the steering upper bracket. • Tighten the front fork lower clamp bolts 5 to the specified torque.

  • Page 128: Location Of Electrical Components

    VL1500K5 (’05-MODEL) LOCATION OF ELECTRICAL COMPONENTS 1 Fuel pump and level gauge (!Page 95) 9 TO sensor (!Page 70) 2 TP sensor (!Page 53) 0 Starter motor 3 IAP sensor (Front) (!Page 49) A Oil pressure switch 4 Ignition coil (#2)
  • Page 129 VL1500K5 (’05-MODEL) 1 Fuel injector (#1 & #2)(!Page 84) 9 GP switch (!Page 82) 2 STP sensor (!Page 77) 0 HO2 sensor (For E-02, 19, 24) (!Page 87) 3 STV actuator (!Page 74) A Ignition coil (#1) 4 IAP sensor (Rear) (!Page 49)

  • Page 130: Charging System

    VL1500K5 (’05-MODEL) CHARGING SYSTEM INSPECTION GENERATOR COIL RESISTANCE • Remove the seats. (!Page 121) • Remove the speedometer and fuel inlet cover, frame head covers and frame upper covers. (!VL1500 Service Manual 6-3) • Disconnect the generator coupler 1. • Measure the resistance among the three lead wires.
  • Page 131 VL1500K5 (’05-MODEL) REGULATOR/RECTIFIER • Remove the secondary gear case cover. (!VL1500 Service Manual 3-7) • Disconnect the couplers and remove the regulator/rectifier 1. • Measure the voltage between the terminals using the multi circuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 132: Automatic Decompression System/Starter System And Side-Stand Ignition Interlock System

    VL1500K5 (’05-MODEL) AUTOMATIC DECOMPRESSION SYSTEM/STARTER SYSTEM AND SIDE-STAND IGNITION INTERLOCK SYSTEM Turn signal/ Engine stop side-stand relay switch IG. switch Fuse 30A Fuse 15A Automatic Starter relay decompression relay Fuse 15A Neutral Automatic indicator Side- Starter Neutral decom- light stand...
  • Page 133 VL1500K5 (’05-MODEL) SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one.

  • Page 134: Ignition System

    VL1500K5 (’05-MODEL) IGNITION SYSTEM Engine stop switch Side- stand Power source relay circuit Ignition coil Spark plug Fuse sensor Wave form arrangement Ignition circuit switch Fuse Battery Throttle Gear Engine position position oil temp. sensor switch sensor NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 5 800 –...
  • Page 135 VL1500K5 (’05-MODEL) Step 2 1) Measure the battery voltage between input lead wires at the ECM with the ignition switch in the “ON” position. (E-02, 19, 24: O/G and B/W, E-03, 28, 33: O/W and B/W) Is the voltage OK? Go to Step 3.
  • Page 136 VL1500K5 (’05-MODEL) INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the frame head covers and frame upper covers. (!VL1500 Service Manual 6-3) • Remove the cylinder head side caps and disconnect the spark plug caps. (!VL1500%Service Manual 3-8) • Connect new spark plugs to each spark plug cap and ground them to the cylinder head.
  • Page 137 VL1500K5 (’05-MODEL) IGNITION COIL RESISTANCE • Remove the frame head covers and frame upper covers. (!VL1500 Service Manual 6-3) • Remove the cylinder head side caps and disconnect the Ω spark plug caps. (!VL1500%Service Manual 3-8) kΩ • Measure the ignition coil resistance in both the primary and secondary windings.
  • Page 138 VL1500K5 (’05-MODEL) • Shift the transmission into the neutral and turn ignition switch “ON”. • Crank the engine a few seconds with the starter motor by depressing starter button and check the CKP sensor peak voltage. • Repeat the above procedure a few times and measure the highest peak voltage.

  • Page 139: Speedometer

    VL1500K5 (’05-MODEL) SPEEDOMETER DESCRIPTION This speedometer mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emit- ting Diode). This speedometer is light, thin and of high response compared to those currently in use because of this composition.
  • Page 140 VL1500K5 (’05-MODEL) REMOVAL AND DISASSEMBLY • Remove the seats. (!Page 121) • Remove the speedometer and fuel inlet cover. (!VL1500 Service Manual 6-3) • Remove the speedometer 1. When disconnecting and reconnecting the speedome- ter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
  • Page 141 VL1500K5 (’05-MODEL) INSPECTION LED (LIGHT EMITTING DIODE) Check that the LEDs illuminate (FI light and Oil pressure indica- tor light) immediately after turning the ignition switch on. Also, check the other LEDs for their lighting (Neutral indicator light, High-beam indicator light and turn signal indicator light) in accor- dance with their switch positions.

  • Page 142: Relays

    VL1500K5 (’05-MODEL) SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of coupler 1. If the speedometer sensor and connection are all right, replace the meter with a new one. SPEEDOMETER SENSOR •...

  • Page 143: Switches

    VL1500K5 (’05-MODEL) SWITCHES inspect each switch for continuity with the multi-circuit tester. If any abnormality is found, replace the respec- tive switch assemblies with new ones. # 09900-25008: Multi-circuit tester set HAZARD IGNITION SWITCH Color Color Position Position LOCK FRONT BRAKE SWITCH...

  • Page 144: Battery

    VL1500K5 (’05-MODEL) BATTERY SPECIFICATIONS Type designation FTZ16-BS-1 Capacity 12 V, 64.8 kC (18 Ah)/10 HR a Anode plates e Stopper b Separator (fiberglass plate) f Filter c Cathode plates g Terminal d Upper cover breather h Safety valve...

  • Page 145: Wiring Harness, Cable And Hose Routing

    VL1500K5 (’05-MODEL) WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Starter motor 6 N . m (0.6 kgf-m, 4.5 lb-ft) Ground wire Speed sensor 6 N . m (0.6 kgf-m, 4.5 lb-ft) Oil pressure switch 14 N . m (1.4 kgf-m,...
  • Page 146 VL1500K5 (’05-MODEL) Clutch hose High-tension cord Frame Clamp Wiring harness Clamp Set the clamp between the HO2 sensor Wiring harness (For E-02, 19, 24) IAP sensor and horn bracket. Generator coupler Don’t set lead wire on pipe. Wiring harness (Except TO sensor)
  • Page 147 VL1500K5 (’05-MODEL) Clamp Clamp Handle switch (R, L) Handle switch Boots Brake hose Clamp Clutch hose Wiring harness Front turn (R, L) Handle switch (R, L) Clamp Horn lead wire (For E-03, 24, 28, 33) Clamp Horn (For E-03, 24, 28, 33)
  • Page 148 VL1500K5 (’05-MODEL) CABLE AND HOSE ROUTING Wiring harness Wiring harness Throttle cable No. 2 Throttle cable No. 1 Clutch hose Brake hose 40 mm 160 mm (1.57 in) (6.30 in) Throttle cable No. 1 Clutch hose 0 – 2 mm 0 –...

  • Page 149: Front Brake Hose Routing

    VL1500K5 (’05-MODEL) FRONT BRAKE HOSE ROUTING 35 ˚ After the brake hose union has contacted the stopper, Pass through the brake hose inside of the tighten the union bolt to the specified torque. hose guide. After positioning the hose clamp with stopper, tighten Bind the brake hose together with the wire the clamp bolt.

  • Page 150: Rear Brake Hose Routing

    VL1500K5 (’05-MODEL) REAR BRAKE HOSE ROUTING 42 ˚ After the brake hose union has contacted the stopper, After positioning the clamp with the stopper, tighten the union bolt. tighten the clamp bolt. Brake hose must be passed over the brake support Brake hose boss and caliper bracket.
  • Page 151 VL1500K5 (’05-MODEL) FUEL SYSTEM HOSE ROUTING & 1 Fuel feed hose 8 PCV (Breather) hose 2 IAP sensor vacuum hose (Rear cylinder) 9 Air cleaner box ITEM N·m kgf-m lb-ft 3 IAP sensor vacuum hose (Front cylinder) 0 IAT sensor 14.4...
  • Page 152 VL1500K5 (’05-MODEL) The ends of the clamp should face left side. The ends of the clamp The ends of the clamp should face right side. should face right side. The clamp bolt head sould face downward. 15 N . m (0.15 kgf-m, 1.0 lb-ft)
  • Page 153 VL1500K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 20 – 40 mm (0.79 – 1.57 in) 20 – 40 mm (0.79 – 1.57 in) 15 – 20 mm 15 – 20 mm (0.59 – 0.79 in) (0.59 – 0.79 in)

  • Page 154: Exterior Parts Installation

    VL1500K5 (’05-MODEL) EXTERIOR PARTS INSTALLATION METER/FUEL INLET COVER INSTALLATION (USA) (Others) (USA) (Others) 1 Frame upper cover (L) 5 Fuel lid hinge bracket 2 Frame upper cover (R) 6 Fuel lid 3 Speedometer/Fuel inlet cover 7 Fuel lid cover 4 Speedometer switch cover *1 Outside *2 Apply an adhesive agent.
  • Page 155 VL1500K5 (’05-MODEL) FRAME UPPER COVER INSTALLATION 1 Cushion seat 4 Molding 2 Apply an adhesive agent. 5 Bend up the stay. 3 Cushion rubber 6 50 mm (2.0 in)
  • Page 156 VL1500K5 (’05-MODEL) FRAME HEAD COVER INSTALLATION 1 Cushion seat 3 3 mm (0.12 in) 2 Apply an adhesive agent.

  • Page 157: Brake Pedal Installation

    VL1500K5 (’05-MODEL) GREASE-UP POINTS 50 N . m (5.0 kgf-m, 36.0 lb-ft) BRAKE PEDAL INSTALLATION × × × × × × Brake pedal height: 98 mm (3.86 in) × Apply an adhesive agent.

  • Page 158: Special Tools

    VL1500K5 (’05-MODEL) SPECIAL TOOLS 09900-25009 09900-28630 Needle pointed TPS test wire har- 09904-41010 99565-01010-004 09915-74511 probe set ness SDS set tool CD-ROM Ver. 4 Oil pressure gauge 09940-40211 09940-40220 09930-82720 Fuel pressure Fuel pressure gauge 09930-11950 Mode selection gauge adapter...

  • Page 159: Tightening Torque

    VL1500K5 (’05-MODEL) TIGHTENING TORQUE * FI SYSTEM AND INTAKE AIR SYSTEM N·m kgf-m lb-ft ITEM IAT sensor 14.4 HO2 sensor (For E-02, 19, 24) 18.0 EOT sensor 16.0 Fuel pump mounting bolt STPS mounting screw 0.35 TPS mounting screw 0.35...

  • Page 160: Service Data

    VL1500K5 (’05-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.3) — (1.6) Lash-adjuster plunger stroke 0 – 0.5 — (0 – 0.02) Valve guide to valve stem 0.010 – 0.037 — clearance (0.0004 – 0.0015) 0.040 –...
  • Page 161 VL1500K5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height * 35.320 – 35.370 * 35.02 (1.3905 – 1.3925) (1.379) 36.880 – 36.930 36.58 (1.4521 – 1.4537) (1.440) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN.
  • Page 162 VL1500K5 (’05-MODEL) ITEM STANDARD LIMIT Piston ring end gap 0.30 – 0.45 0.70 (0.012 – 0.018) (0.028) 0.45 – 0.60 1.00 (0.018 – 0.024) (0.039) Piston ring to groove clearance 0.180 — (0.007) 0.150 — (0.006) Piston ring groove width 1.210 –...

  • Page 163: Oil Pump

    VL1500K5 (’05-MODEL) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.154 (76/51 × 31/40) — Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm , 50 psi) Below 650 kPa (6.5 kgf/cm , 92 psi) —...
  • Page 164 VL1500K5 (’05-MODEL) * INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR ITEM SPECIFICATION NOTE Approx. 11.7 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 168 ml (5.7/5.9 US/lmp oz) and more/10 sec. Fuel pressure regulator operat- Approx.

  • Page 165: Spark Plug

    VL1500K5 (’05-MODEL) * THROTTLE BODY ITEM SPECIFICATION ID No. 10F0 (For E-02, 19, 03, 24, 28), 10F1 (For E-33) Bore size 36 mm Fast idle r/min 1 400 – 2 000 r/min When cold engine Idle r/min 1 000 ± 100 r/min Throttle cable play 2.0 –...

  • Page 166: Position/Parking Light

    VL1500K5 (’05-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight ← ← Position/Parking light * 12/5 ← ← Brake light/Taillight 21/5 ← Turn signal light Front 21/5 ← ← Rear ← ← Speedometer light * LED ←...

  • Page 167: Tire Pressure

    SAE 10W-40, API SF or SG Engine oil capacity 3 700 ml Change (3.9/3.3 US/lmp qt) Filter 4 300 ml change (4.5/3.8 US/lmp qt) 5 000 ml Overhaul (5.3/4.4 US/lmp qt) Front fork oil type SUZUKI FORK OIL SS-08 (#10) or equivalent fork oil...
  • Page 168 VL1500K5 (’05-MODEL) ITEM STANDARD LIMIT Front fork oil capacity (each leg) *416 ml (14.1/14.6 US/lmp oz) Bevel gear oil type Hypoid Gear oil #90 API GL-5 Bevel gear oil capacity 200 – 220 ml Final (6.8/7.0 – 7.4/7.7 US/lmp oz)

  • Page 169: Emission Control Systems

    VL1500K5 (’05-MODEL) EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VL1500K5 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...

  • Page 170: Crankcase Emission Control System

    VL1500K5 (’05-MODEL) CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crank- case, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.
  • Page 171 VL1500K5 (’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 through the PAIR solenoid valve and PAIR reed valve.

  • Page 172: Noise Emission Control System

    VL1500K5 (’05-MODEL) NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Local 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...

  • Page 173: Pair (Air Supply) System Inspection

    VL1500K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES AND PIPES • Remove the PAIR cover. (!Page 14) • Inspect the hoses for wear or damage. • Inspect that the hoses for secure connection. PAIR REED VALVE • Remove the PAIR control solenoid valve. (!Page 14) •...
  • Page 174 VL1500K5 (’05-MODEL) • Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow. • If air does not flow out, the solenoid valve is in normal condi- tion. • Check the resistance between the terminals of the PAIR con- trol solenoid valve.

  • Page 175: Pair (Air Supply) System Diagram

    VL1500K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM DIAGRAM A FRESH AIR 4 No. 2 cylinder B EXHAUST GAS *1 From air cleaner 1 PAIR control solenoid valve *2 To No. 1 cylinder 2 PAIR reed valve *3 To No. 2 cylinder...

  • Page 176: Pair (Air Supply) System Hose Routing

    VL1500K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 20 – 40 mm (0.79 – 1.57 in) 20 – 40 mm (0.79 – 1.57 in) 15 – 20 mm 15 – 20 mm (0.59 – 0.79 in) (0.59 – 0.79 in)

  • Page 177: Heated Oxgen Sensor (Ho2S) Inspection (For E-02, 19, 24)

    VL1500K5 (’05-MODEL) HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) The HO2 sensor coupler is located at the rear side of the fuel tank. (!Page 87) • Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 (P0130/P0135).

  • Page 178: Wiring Diagram

    WIRING DIAGRAM E-02, 19, 24 HANDLEBAR SWITCH (R) SPEEDOMETER HAZARD ENGINE STOP STARTER FRONT BRAKE : TURN SIGNAL INDICATOR LIGHT SWITCH SWITCH BUTTON LIGHT SWITCH SIDE-STAND : HIGH BEAM INDICATOR LIGHT PUSH SWITCH : OIL PRESSURE INDICATOR LIGHT DECOMP FUEL PUMP : NEUTRAL INDICATOR LIGHT SPEED SOLENOID...
  • Page 179 E-03, 28, 33 HANDLEBAR SWITCH (R) SPEEDOMETER HAZARD ENGINE STOP STARTER FRONT BRAKE SWITCH SWITCH BUTTON LIGHT SWITCH : TURN SIGNAL INDICATOR LIGHT SIDE-STAND : HIGH BEAM INDICATOR LIGHT PUSH SWITCH : OIL PRESSURE INDICATOR LIGHT DECOMP FUEL PUMP : NEUTRAL INDICATOR LIGHT SPEED SOLENOID REAR BRAKE...
  • Page 180 Prepared by May, 2004 Part No. 99501-39550-01E Printed in Japan...
  • Page 181 Printed in Japan...

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