Suzuki VL800 Supplementary Service Manual
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Suzuki VL800 Supplementary Service Manual

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USE THIS MANUAL WITH:
VL800 SERVICE MANUAL (99500-38043-01E)
9 9 5 0 1 - 3 8 0 8 0 - 0 1 E

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Summary of Contents for Suzuki VL800

  • Page 1 USE THIS MANUAL WITH: VL800 SERVICE MANUAL (99500-38043-01E) 9 9 5 0 1 - 3 8 0 8 0 - 0 1 E...
  • Page 2 These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service VL800 in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control,...

  • Page 3: Table Of Contents

    The following codes stand for the applicable country (-ies) and area (-s). CODE COUNTRY or AREA EFFECTIVE FRAME NO. Japan --------------- E-02 U.K. JS1BM111200101117- E-19 JS1BM111100112285- E-24 Australia JS1BM121300100613- E-03 U.S.A. (Except for california) JS1VS55A 52100001- E-28 Canada JS1VS55A 52100001- E-33 California (U.S.A.) JS1VS55A 52100001-  COPYRIGHT SUZUKI MOTOR CORPORATION 2004...

  • Page 4: Specifications

    VL800K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 510 mm (98.8 in) Overall width ..................985 mm (38.8 in) Overall height ..................1 100 mm (43.3 in) Wheelbase ..................1 655 mm (65.2 in) Ground clearance ................140 mm ( 5.5 in) Seat height.

  • Page 5: Abbreviations Used In This Manual

    VL800K5 (’05-MODEL) ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Engine Control Module : Alternating Current Engine Control Unit (ECU) : Air Cleaner, Air Cleaner Box (FI Control Unit) : American Petroleum Institute ECT Sensor : Engine Coolant Temperature ATDC : After Top Dead Center Sensor (ECTS), Water Temp.
  • Page 6 : Oil Pressure Switch : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor...

  • Page 7: Sae-To-Former Suzuki Term

    VL800K5 (’05-MODEL) 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...
  • Page 8 VL800K5 (’05-MODEL) SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control ------- Ignition Control Electronic Spark Advance (ESA) Ignition Control Module ------- Intake Air Temperature Intake Air Temperature (IAT), Air Temperature Malfunction Indicator Lamp LED Lamp Malfunction Indicator Lamp (MIL)

  • Page 9: Service Data

    VL800K5 (’05-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.18) ---- (1.02) Valve clearance (when cold) 0.08 – 0.13 ---- (0.003 – 0.005) 0.17 – 0.22 ---- (0.007 – 0.009) Valve guide to valve stem 0.010 –...
  • Page 10 VL800K5 (’05-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.95 – 35.99 35.65 (1.415 – 1.417) (1.404) Front 36.92 – 36.96 36.62 (1.454 – 1.455) (1.442) 35.50 – 35.54 35.20 (1.398 – 1.399) (1.386) Rear 36.52 –...
  • Page 11 VL800K5 (’05-MODEL) ITEM STANDARD LIMIT Piston ring free end gap Approx. 9.6 (0.38) (0.30) Approx. 11.8 (0.46) (0.37) Piston ring end gap 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) 0.20 – 0.35 0.70 (0.008 – 0.014) (0.028) Piston ring to groove clearance 0.180 ---- (0.007)

  • Page 12: Oil Pump

    10 VL800K5 (’05-MODEL) ITEM STANDARD LIMIT Crankshaft thrust bearing 1.925 – 2.175 ---- thickness (0.0758 – 0.0856) Crankshaft thrust clearance 0.05 – 0.10 ---- (0.002 – 0.004) Crankshaft runout 0.05 ---- (0.002) OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60 °C, 140 °F) 350 –...

  • Page 13: Shaft Drive

    VL800K5 (’05-MODEL) ITEM STANDARD LIMIT Shift fork groove width 5.50 – 5.60 No.1 ---- (0.217 – 0.220) 4.50 – 4.60 No.2 ---- (0.177 – 0.181) Shift fork thickness 5.30 – 5.40 No.1 ---- (0.209 – 0.213) 4.30 – 4.40 No.2 ---- (0.169 –...
  • Page 14 12 VL800K5 (’05-MODEL) * INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE 11 – 13 Ω at 20 °C (68 °F) * Injector resistance * Fuel pump discharge amount Approx. 168 ml (5.7/5.9 US/lmp oz) and more/10 sec. * Fuel pressure regulator operating set Approx.
  • Page 15 VL800K5 (’05-MODEL) * THROTTLE BODY 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 –...
  • Page 16 14 VL800K5 (’05-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 28, 33 E-24 Others ← ← Headlight 60 W ← ← 55 W Position/Parking light ← ← Brake light/Taillight 21/5 W Turn signal light 21/5 W (Front), ← 21 W 21 W (Rear) ←...
  • Page 17 (21.73) (21.29) Front fork oil level (without spring) ---- (6.96) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil ---- Front fork oil capacity (each leg) 412 ml ---- (24.0/25.0 US/Imp oz) Front fork inner tube outside diam.
  • 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 E-03, 28, 33 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion...

  • Page 19: Periodic Maintenance Chart

    VL800K5 (’05-MODEL) PERIODIC MAINTENANCE CHART Interval miles 4 000 7 500 11 000 14 500 1 000 6 000 12 000 18 000 24 000 Item months Air cleaner element ---- Spark plug ---- Valve clearance ---- ---- Engine oil Engine oil filter ---- ----...

  • 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 click is felt.
  • Page 21 VL800K5 (’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. Connect the probe as shown to avoid opening of female ter- minal.
  • 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. INCORRECT • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.

  • Page 23: Electrical Circuit Inspection Procedure

    VL800K5 (’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 circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
  • 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.
  • Page 25 VL800K5 (’05-MODEL) 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/couplers of those parts.
  • 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 the tester to burnout.

  • Page 27: Fi System Technical Features

    VL800K5 (’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 intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 28: Injection Stop Control

    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). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.

  • Page 29: Fi System Parts Location

    VL800K5 (’05-MODEL) 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)
  • 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)

  • Page 31: Fi System Wiring Diagram

    VL800K5 (’05-MODEL) FI SYSTEM WIRING DIAGRAM...

  • 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, the dealer mode is prepared.

  • Page 33: Dealer Mode

    VL800K5 (’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 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 34 32 VL800K5 (’05-MODEL) CODE MALFUNCTION PART REMARKS None No defective part Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator Intake air pressure sensor (IAPS) For Front cylinder Throttle position sensor (TPS) Engine coolant temperature sensor (ECTS) Intake air pressure sensor (IAPS) For Rear cylinder Intake air temperature sensor (IATS) Tip-over sensor (TOS)

  • Page 35: Tps Adjustment

    VL800K5 (’05-MODEL) 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.

  • 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. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”...

  • Page 37: Fi System Troubleshooting

    VL800K5 (’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 38: Visual Inspection

    36 VL800K5 (’05-MODEL) MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F/ °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill...
  • Page 39 VL800K5 (’05-MODEL) 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 erase the memorized information in ECM memory.

  • Page 40: Use Of Sds Diagnostic Procedures

    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 code (C00) is indicated, the previ- ous malfunction history code still remains stored in the ECM.
  • Page 41 VL800K5 (’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 42: Show Data When Trouble

    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 possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
  • Page 43 VL800K5 (’05-MODEL) • Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure #1” or “Failure #2” can be selected.

  • Page 44: Ecm Terminal

    42 VL800K5 (’05-MODEL) ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) Ignition switch signal (AT) IAT sensor signal (IAT) ECT sensor signal (ECT) 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 45: Malfunction Code And Defective Condition

    VL800K5 (’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 44 VL800K5 (’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 VL800K5 (’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 P0705 If lower than the above value, C31 (P0705) is indicated.
  • Page 48 46 VL800K5 (’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 VL800K5 (’05-MODEL) 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 –...
  • 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 –...
  • Page 51 VL800K5 (’05-MODEL) “C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C13/C17 IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.1 V Sensor voltage < 4.8 V •...
  • 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/Br wires).
  • Page 53 VL800K5 (’05-MODEL) Is the voltage OK? • 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 connection are OK, intermittent trou- ble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection.
  • Page 54 52 VL800K5 (’05-MODEL) “C14” (P0120) 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. ing and opening calculated by ECM is •...
  • Page 55 VL800K5 (’05-MODEL) Step 1 (When indicating P0120-H:) 1) Remove the fuel tank. ($Page 93) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
  • Page 56 54 VL800K5 (’05-MODEL) Step 1 (When indicating P0120-L:) 1) Remove the fuel tank. ($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.
  • Page 57 VL800K5 (’05-MODEL) 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 and Black 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.
  • Page 59 VL800K5 (’05-MODEL) “C15” (P0115) ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. Sensor voltage < 4.6 V • ECM malfunction. P0115 Sensor voltage is higher than specified •...
  • Page 60 58 VL800K5 (’05-MODEL) Step 1 (When indicating P0115-H:) 1) Remove the fuel tank. ($Page 93) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
  • Page 61 VL800K5 (’05-MODEL) Step 1 (When indicating P0115-L:) 1) Remove the fuel tank. ($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.
  • 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 kΩ at 20 °C (68 °F) (Terminal – Terminal) " 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) 3) Remove the ECT sensor.
  • Page 63 VL800K5 (’05-MODEL) “C21” (P0110) 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 64 62 VL800K5 (’05-MODEL) Step 1 (When indicating P0110-H:) 1) Remove the air cleaner box. ($Page 103) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
  • Page 65 VL800K5 (’05-MODEL) Step 1 (When indicating P0110-L:) 1) Remove the air cleaner box. ($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.
  • 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 kΩ at 20 °C (68 °F) (Terminal – Terminal) " 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Is the resistance OK? •...
  • Page 67 VL800K5 (’05-MODEL) “C23” (P1651) 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 68 66 VL800K5 (’05-MODEL) Step 1 (When indicating P1651-H:) 1) Remove the right frame cover. ($VL800K1 7-2) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
  • Page 69 VL800K5 (’05-MODEL) Step 1 (When indicating P1651-L:) 1) Remove the right frame cover. ($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.
  • 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 –...
  • Page 71 VL800K5 (’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. STV ACTUATOR STVA.
  • 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) and (between Green wire terminal and W/B wire terminal) ! STVA resistance: Approx.
  • Page 73 VL800K5 (’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 STVA, the function is normal.
  • Page 74 72 VL800K5 (’05-MODEL) “C29” (P1654) 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. ing and opening calculated by ECM is •...
  • Page 75 VL800K5 (’05-MODEL) Step 1 (When indicating P1654-H:) 1) Remove the fuel tank. ($Page 93) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
  • Page 76 74 VL800K5 (’05-MODEL) Step 1 (When indicating P1654-L:) 1) Remove the fuel tank. ($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.
  • Page 77 VL800K5 (’05-MODEL) 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 Yellow and Black wires).
  • 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 + Y/W and - B/Br wires) when the secondary throttle valve is full closed and opened by moving the fast idle...
  • Page 79 VL800K5 (’05-MODEL) Is the voltage OK? • 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 wire harness for open circuit and poor connection.
  • Page 80 78 VL800K5 (’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 81 VL800K5 (’05-MODEL) 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 coupler between Pink wire and ground, when shifting the gearshift lever from 1st to Top.
  • Page 82 80 VL800K5 (’05-MODEL) “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted 4 times or more continuously. • Injector malfunction. •...
  • Page 83 VL800K5 (’05-MODEL) 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.
  • Page 84 82 VL800K5 (’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 85 VL800K5 (’05-MODEL) “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short. ECM. • PAIR control solenoid valve malfunction. • ECM malfunction. Engine stop Ignition Side-stand relay...
  • 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.
  • Page 87 VL800K5 (’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 “PAIR Sol operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
  • Page 88 86 VL800K5 (’05-MODEL) “C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (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 VL800K5 (’05-MODEL) 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.
  • 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 measure the heater voltage between W/B wire (ECM side) and ground.
  • Page 91 VL800K5 (’05-MODEL) 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 –...

  • 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 The intake air pressure sensor is installed on the air intake pipe.

  • Page 93: Stp Sensor Adjustment

    VL800K5 (’05-MODEL) 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. •...

  • 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 and pressurized fuel flows into the injector installed in the fuel delivery pipe.

  • Page 95: Fuel System

    VL800K5 (’05-MODEL) 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 twisted.

  • Page 96: Fuel Pressure Inspection

    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.

  • Page 97: Fuel Pump Inspection

    VL800K5 (’05-MODEL) 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.

  • Page 98: Fuel Pump Relay Inspection

    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.
  • Page 99 VL800K5 (’05-MODEL) 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...

  • Page 100: Fuel Pump Removal And Disassembly

    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. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. •...

  • Page 101: Fuel Mesh Filter Inspection And Cleaning

    VL800K5 (’05-MODEL) • 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.
  • Page 102 VL800K5 (’05-MODEL) FUEL PUMP REASSEMBLY AND INSTALLA- TION Install the fuel pump in the reverse order of removal and disas- sembly. Pay attention to the following points: • Install a new bushing 1 to the fuel pump. Use the new bushing to prevent fuel leakage.
  • Page 103 VL800K5 (’05-MODEL) • 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) The O-ring must be replaced with a new one to prevent fuel leakage.

  • Page 104: Throttle Body

    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...

  • Page 105: Air Cleaner Box Removal

    VL800K5 (’05-MODEL) 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. •...

  • Page 106: Throttle Body Removal

    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. •...

  • Page 107: Throttle Body Disassembly

    VL800K5 (’05-MODEL) 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. •...
  • Page 108 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 identifications when removing.

  • Page 109: Throttle Body Cleaning

    VL800K5 (’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 manufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

  • Page 110: Throttle Body Reassembly

    NOTE: * 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. TP sensor setting procedure. ( $ Page 118) , 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 111 VL800K5 (’05-MODEL) • 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. Replace the O-ring and cushion seal with the new ones. • Install the fuel injectors 3 by pushing them straight to each throttle body.

  • Page 112: Throttle Body Installation

    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. TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.

  • Page 113: Fuel Injector Removal

    VL800K5 (’05-MODEL) 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 sensor resistance (between Yel- low wire terminal and Black wire terminal).

  • Page 114: Fuel Injector Inspection

    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.

  • Page 115: Fast Idle

    VL800K5 (’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. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
  • Page 116 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 STV fully open 1.20 V Idle...

  • Page 117: Throttle Valve Synchronization

    VL800K5 (’05-MODEL) 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. •...
  • Page 118 VL800K5 (’05-MODEL) Step 3 • Turn in two idle air screws to the complete close position. • Check for difference of vacuum between front cylinder and rear cylinder. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.
  • Page 119 VL800K5 (’05-MODEL) • Connect a tachometer. • Start up the engine and keep it running at 1 100 rpm by turn- ing throttle stop screw 2. Avoid drawing dirt into the throttle body while running the engine without intake pipe and air cleaner box. Dirt drawn into the engine will damage the internal engine parts.
  • Page 120 VL800K5 (’05-MODEL) THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS 1 setting condition.

  • Page 121: Emission Control Systems

    VL800K5 (’05-MODEL) 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...
  • Page 122 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: Noise Emission Control System

    VL800K5 (’05-MODEL) 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 device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2.

  • Page 124: Pair (Air Supply) System And Emission Control System Inspection

    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.

  • Page 125: Pair Control Solenoid Valve

    VL800K5 (’05-MODEL) 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 • Disconnect the PAIR hoses. • Remove the PAIR control solenoid valve 3. •...

  • Page 126: Evaporative Emission Control System Inspection (Only For E-33)

    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 or damage.

  • Page 127: Tightening Torque

    VL800K5 (’05-MODEL) TIGHTENING TORQUE CHASSIS N·m kgf-m lb-ft ITEM Front axle 47.0 Front axle pinch bolt 24.0 Brake disc bolt 16.5 Front fork cap bolt 33.1 Front fork spring stopper nut 25.5 Front fork damper rod bolt 14.5 *Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 24.0...

  • Page 128: Wiring Harness, Cable And Hose Routing

    VL800K5 (’05-MODEL) WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Wiring harness Front turn signal light (L & R) Regulator/Rectifier Handlebar switch (L & R) Speed sensor Clamp Clamp Clamp Wiring harness PAIR control solenoid valve leadwire Ignition oil leadwire To generator Clamp To wiring harness...
  • Page 129 VL800K5 (’05-MODEL) Injector To speedometer stoplamp switch To Horn Clamp TO sensor Pass through inside of the cover Clamp IAT sensor To HO2S sensor Wiring harness Frame Radiator...
  • Page 130 VL800K5 (’05-MODEL)

  • Page 131: Cable Routing

    VL800K5 (’05-MODEL) CABLE ROUTING Throttle cable No.2 (Returning cable) Clamp Throttle cable No.1 Wiring (Pulling cable) harness Throttle cable No.2 Clutch cable Throttle White Brake cable No.1 tape Clutch hose Cable guide cable Clutch 0 – 2 mm (0 – 0.08 in) Wiring cable *3 harness...

  • Page 132: Cooling System Hose Routing

    VL800K5 (’05-MODEL) COOLING SYSTEM HOSE ROUTING...

  • Page 133: Speed Sensor Lead Wire Routing

    VL800K5 (’05-MODEL) SPEED SENSOR LEAD WIRE ROUTING Headlight housing Brake hose Speed sensor 30 mm lead wire (1.18 in) Clamp Speed sensor guide hook Speed sensor lead wire Speed sensor lead guide Pass through the speed sensor lead wire between the headlight housing and brake hose.

  • Page 134: Fuel Tank Installation

    VL800K5 (’05-MODEL) FUEL TANK INSTALLATION Cut the clamp Frame...

  • Page 135: Brake Pedal Installation

    VL800K5 (’05-MODEL) BRAKE PEDAL INSTALLATION 5 mm (0.20 in) 98 mm (3.86 in) *1 Apply an adhesive agent. HANDLEBAR BALANCER Throttle grip Handlebar Handle balancer expander Handlebar balancer Screw 5.5 N·m (0.5 kgf-m, 4.0 lb-ft) 1 mm (0.04 in): Right side 0 mm (0 in): Left side...

  • Page 136: Pair (Air Supply) System Diagram

    VL800K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM DIAGRAM 1 PAIR control solenoid valve *1 From air cleaner. 2 PAIR reed valve *2 To #1 cylinders. A FRESH AIR *3 To #2 cylinders.

  • Page 137: Pair (Air Supply) System Hose Routing

    VL800K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING 1 PAIR control solenoid valve *2 Matching mark Throttle body Do not contact the hose and throttle cable drum. Bolt The sealant side should face PAIR pipe side. To air cleaner box. With the bolt lightly contacted with the PAIR pipe, tighten the bolt.

  • Page 138: Evap Canister Hose Routing (Only For E-33)

    VL800K5 (’05-MODEL) EVAP CANISTER HOSE ROUTING (Only for E-33) 1 Three way joint 5 EVAP Canister Wiring harness Pass through the purge hose over the wiring harness. 3 Frame *2 White paint mark should face upside. 4 Fuel shut-off valve *3 To three way joint.

  • Page 139: Special Tools

    VL800K5 (’05-MODEL) SPECIAL TOOLS 09900-25009 09913-13121 Needle pointed 09904-41010 99565-01010-004 Vacuum balancer 09930-11950 probe set SDS Set CD-ROM Ver.4 gauge Torx wrench 09940-40211 09940-40220 09930-82720 Fuel pressure gauge Fuel pressure gauge Mode select switch adaptor hose attachment NOTE: When ordering the special tool, please confirm whether it is available or not.
  • Page 140 VL800K5 (’05-MODEL) WIRE COLOR : Black : Gray : Red : Blue : Light blue : White : Brown : Light green : Yellow : Dark green : Orange : Green : Pink B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer B/Lg...

  • Page 141: Wiring Diagram

    WIRING DIAGRAM E-02, 19, 24 Wiring diagrams wire color, refer to section “WIRE COLOR”. TEMP : ENGINE COOLANT TEMP. WARNING LIGHT : FI LIGHT HANDLEBAR SWITCH (R) SPEEDOMETER : FUEL WARNING LIGHT : TURN SIGNAL INDICATOR LIGHT ENGINE FI/TEMP/OIL : HI-BEAM INDICATOR LIGHT HAZARD STOP STARTER...
  • Page 142 E-03, 28, 33 TEMP : ENGINE COOLANT TEMP. WARNING LIGHT : FI LIGHT HANDLEBAR SWITCH (R) SPEEDOMETER : FUEL WARNING LIGHT : TURN SIGNAL INDICATOR LIGHT ENGINE FI/TEMP/OIL : HI-BEAM INDICATOR LIGHT STARTER FRONT BRAKE HAZARD STOP BUTTON SWITCH : NEUTRAL INDICATOR LIGHT SWITCH SWITCH : OIL INDICATOR LIGHT...
  • Page 143 Prepared by JUNE, 2004 Part No.99501-38080-01E Printed in Japan...
  • Page 144 Printed in Japan...

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