Page 1 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION Revised 09/07...
Page 3 SUPPLEMENTS VL800K2 ('02- MODEL) VL800K3 ('03- MODEL) VL800K4 ('04- MODEL) VL800K5 ('05- MODEL) VL800TK5 ('05- MODEL) VL800/TK6 ('06- MODEL) VL800/TK7 & TK8 ('07&’08- MODEL ) VL800/C/TK9 (”09 MODEL) WIRING DIAGRAM...
Page 4: How To Use This Manual
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 5 Use fork oil. otherwise specified. 99000-99001 SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25030 Apply SUZUKI MOLY PASTE.
Page 6 Use fork oil. otherwise specified. 99000-99001-SS8 Apply molybdenum oil solution. Apply or use brake fluid. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25010 Apply SUZUKI MOLY PASTE.
Page 7: General Information
GENERAL INFORMATION GENERAL INFORMATION CONTENTS...
Page 8: General Precautions
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 9 GENERAL INFORMATION 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
Page 10: Serial Number Location
) method or 91 octane or higher rated by the Research Method. 2. Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.
Page 11: Brake Fluid
Use an antifreeze designed for aluminum radiators. Suzuki recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.
Page 12: Cylinder Identification
1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
Page 13: Information Labels
GENERAL INFORMATION 1-7 INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME E-02 E-03 E-19 E-24 E-28 E-33 Noise label – – – Information label – – – Vacuum hose routing label – – – – – Fuel caution label – –...
Page 14: Dimensions And Dry Mass
1-8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 510 mm (98.818 in) Overall width ..............985 mm (38.779 in) Overall height ..............1 110 mm (43.700 in) Wheelbase ..............1 650 mm (64.960 in) Ground clearnce ............140 mm ( 5.511 in) Seat height ..............
Page 15 GENERAL INFORMATION 1-9 CHASSIS Front suspension ............Telescopic, coil spring, oil damped Rear suspension ............Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle .............. 38° (right & left) Caster ................33° 20’ Trail ................141 mm (3.55 in) Turning radius ...............
Page 16 1-10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 England (UK) E-03 E-19 E-24 Australia E-28 Canada E-33 California...
Page 17: Periodic Maintenance
PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS...
Page 18: Periodic Maintenance Chart
2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and months, whichever comes first. IMPORTANT (USA only): The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations.
Page 19: Lubrication Points
PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Throttle cable Brake lever holder Brake pedal pivot and brake rod link Clutch lever holder Side-stand pivot and spring hook...
Page 20: Air Cleaner
2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. AIR CLEANER • Remove the screws and air cleaner case cover. • Remove the air cleaner element. • Carefully use air hose to blow the dust from the cleaner ele- ment.
Page 21 PERIODIC MAINTENANCE 2-5 • Remove the spark plug caps. • Remove the spark plugs with a spark plug wrench. HEAT RANGE • Check spark plug heat range by observing electrode color. If the electrode of the spark plug is wet appearing or dark color, replace the spark plug with hotter type one.
Page 22: Spark Plug/Ignition Coil/Plug Cap Installation
2-6 PERIODIC MAINTENANCE SPARK PLUG AND IGNITION COIL/PLUG CAP INSTALLATION • Install the spark plugs to the cylinder head with fingers, and then tighten them to the specified torque with a wrench. % Spark plug: 11 N . m (1.1 kgf . m, 8.0 Ib-ft) Do not crossthread or over tighten the spark plug, or the spark plug will damage the aluminum threads of the cyl- inder head.
Page 23 PERIODIC MAINTENANCE 2-7 • Remove all the inspection caps. • Remove all the spark plugs. • Remove the generator cover plug 3 and the timing inspection plug 4. • Rotate the generator rotor to set the No.1 engine’s piston at TDC of the compression stroke.
Page 24: Engine Oil And Oil Filter
2-8 PERIODIC MAINTENANCE Inspect the No.2 engine’s valve clearance as the same manner above. NOTE: FRONT Use the thickness gauge from the arrow marks as shown in the illustration. No. 2 Engine No. 1 Engine ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT •...
Page 25 TER. Other manufacturer’s oil ilters may differ in thread specifications (thread diameter and pitch), filtering per- formance and durability which may lead to engine dam- age or oil leaks. Also, do not use a genuine Suzuki auto- mobile oil filter on this motorcycle.
Page 26: Fuel Hose
2-10 PERIODIC MAINTENANCE FUEL HOSE Inspect the fuel hose 1 for damage and fuel leakage. If any de- fects are found, replace the fuel hose. ENGINE IDLE SPEED NOTE: Warm up the engine before adjusting the engine idle speed. • Start the engine, turn the throttle stop screw and set the engine idle speed as follows.
Page 27: Throttle Cable Play
PERIODIC MAINTENANCE 2-11 THROTTLE CABLE PLAY Adjust the throttle cable play A as follows. MINOR ADJUSTMENT 1st step: • Loosen the lock nut 1 of the throttle returning cable 2 and fully turn in the adjuster 3. 2nd step: • Loosen the lock nut 4 of the throttle pulling cable 5. •...
Page 28 2-12 PERIODIC MAINTENANCE MAJOR ADJUSTMENT • Remove the fuel tank. (!5-3) • Loosen the lock nuts 1 of the throttle returning cable 2. • Turn the returning cable adjuster 3 to obtain proper cable play. • Loosen the lock nuts 4 of the throttle pulling cable 5. •...
Page 29: Cooling System
PERIODIC MAINTENANCE 2-13 COOLING SYSTEM ENGINE COOLANT LEVEL CHECK • Keep the motorcycle upright. • Check the engine coolant level by observing the full and lower lines on the engine coolant reservoir. A Full line B Lower line • If the level is below the lower line, add engine coolant to the full line from the engine coolant reservoir filler.
Page 30 2-14 PERIODIC MAINTENANCE AIR BLEEDING THE COOLING CIRCUIT • Add engine coolant up to the radiator inlet. • Support the motorcycle upright. • Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. • Add engine coolant up to the radiator inlet. •...
Page 31: Final Gear Oil
PERIODIC MAINTENANCE 2-15 FINAL GEAR OIL • Keep the motorcycle upright. • Place an oil pan under the final gear case. Remove the filler cap 1 and drain plug 2 to drain oil. • Refit the drain plug 2. Pour the specified oil (SAE 90 hypoid gear oil with GL-5 under API classification) through the filler hole until the oil level reaches the filler hole.
Page 32 2-16 PERIODIC MAINTENANCE REAR BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Adjust the brake pedal height A by turning the adjuster 2. " Rear brake pedal height : 75 – 85 mm REAR BRAKE ADJUSTING • Adjust the free travel B to 20 – 30 mm by turning the adjusting nut 3.
Page 33 PERIODIC MAINTENANCE 2-17 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
Page 34: Tire Tread Depth
2-18 PERIODIC MAINTENANCE TIRES TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification. ( 09900-20805: Tire depth gauge "...
Page 35: Front Fork
PERIODIC MAINTENANCE 2-19 STEERING The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground.
Page 36: Chassis Bolts And Nuts
2-20 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Check that all chassis bolts and nuts are tightened to their specified torque. The locations of the following nuts and bolts on the motorcycle. N . m kgf . m Item Ib-ft 1 Steering stem head nut 65.0 2 Steering stem lock nut 58.0...
Page 37 PERIODIC MAINTENANCE 2-21...
Page 38: Compression Pressure Check
2-22 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 39: Oil Pressure Check
PERIODIC MAINTENANCE 2-23 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 350 – 650 kPa (3.5 – 6.5 kgf/cm , 50 – 92 psi) at 3 000 r/min., Oil temp. at 60°C (140°F) If the oil pressure is lower or higher than the specification, the following causes may be considered.
Page 40 ENGINE ENGINE CONTENTS...
Page 41 3-2 ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION...
Page 42: Engine Removal And Installation
ENGINE 3-3 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure.
Page 43 3-4 ENGINE • Disconnect the neutral switch lead wire coupler 1. • Disconnect the generator lead wire coupler 2 and the signal generator lead wire coupler 3. • Disconnect the side-stand switch lead wire coupler 4. • Remove the clutch release mechanism. •...
Page 44 ENGINE 3-5 • Remove the air cleaner box bracket. • Disconnect the negative pressure hose 1. • Remove the carburetor. Caburetor removal !5-15 • Remove the spark plug caps. • Remove the right frame cover. • Remove the No. 1 muffler.
Page 45 3-6 ENGINE • Remove the No. 1 exhaust pipe and the No. 2 muffler. • Remove the No.2 exhaust pipe. • Remove the rear clutch cover. • Remove the cooling fan mounting bolts. • Remove the engine mounting bolt 1.
Page 46 ENGINE 3-7 • Remove the frame down tube. • Support the engine with an engine jack. • Remove the engine mounting bolts and nuts. • Gradually lower the engine.
Page 47: Engine Installation
3-8 ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the universal joint. NOTE: Be sure to face the short portion A backward when installing it. • Install the boot. NOTE: Make sure that the “UP”...
Page 48 ENGINE 3-9 NOTE: * The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. * Be sure to use new nuts and tighten them to the specified torque. 50 N . m (5.0 kgf .
Page 49 " Gearshift lever height A Standard: 90 mm (3.5 in) • Apply grease to the push rod and install it. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Apply grease to the clutch release mechanism and install it.
Page 50: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY • Remove the PAIR pipes. • Remove the spark plugs. % 09930-10121: Spark plug wrench set • Remove the valve timing inspection plug 1 and the generator cover cap 2. • Position “RIT” mark on the generator with the center of the valve timing inspection hole.
Page 51 3-12 ENGINE CYLINDER HEAD/CYLINDER • Loosen the water hose clamp screws. • Remove the cylinder head bolts. (Front cylinder) • Remove the cylinder head and cylinder. (Front cylinder) • After unlocking the ratchet, push the cam chain tension ad- juster rod fully. •...
Page 52 ENGINE 3-13 • Remove the cylinder head bolt and nut. (Rear cylinder) • Push the cam chain tension adjuster rod and insert the special tool. % 09918-53810: Chain tensioner lock tool • Remove the cylinder head by removing the cylinder head bolts. •...
Page 53 3-14 ENGINE STARTER MOTOR • Remove the starter motor cover. • Remove the starter motor. CLUTCH • Remove the clutch cover. • Remove the clutch spring mounting bolts and springs diago- nally. • Remove the pressure plate 1.
Page 54 ENGINE 3-15 • Remove the thrust washer 1, bearing 2, push piece 3 and push rod. • Remove the clutch drive and driven plates. • Remove the spring washer 4 and spring washer seat 5. • Remove the clutch sleeve hub nut with the special tool. % 09920-53740: Clutch sleeve hub holder •...
Page 55 3-16 ENGINE • Remove the primary driven gear assembly and the oil pump drive chain. • Remove the thrust washer 1 and spacer 2. OIL PUMP • Remove the oil pump by removing the circlip. % 09900-06107: Snap ring pliers •...
Page 56 ENGINE 3-17 • Remove the gearshift cam plate 1. • Remove the gearshift cam stopper 2. PRIMARY DRIVE GEAR Remove the primary drive gear by removing the primary drive gear bolt with the special tool. % 09930-40113: Rotor holder & This bolt has left-hand thread.
Page 57 3-18 ENGINE NEUTRAL SWITCH • Remove the neutral switch assembly. • Remove the oil pressure switch lead wire. GENERATOR • Remove the generator cover. • Remove the starter motor driven gear and the idle gear. • Loosen the generator rotor bolt. NOTE: When loosen the rotor bolt, do not remove it.
Page 58 ENGINE 3-19 • Remove the cam chain tensioner and the chain. WATER PUMP • Remove the water pump cover. • Remove the water pump assembly. SECONDARY DRIVEN GEAR • Remove the secondary driven gear housing bolts. • Remove the secondary driven gear case.
Page 59 3-20 ENGINE • Remove the secondary driven gear assembly. • Remove the bearing 1. • Remove the oil jet 2. OIL JET • Remove the oil jets. CRANKCASE • Remove the crankcase bolts. • Separate the crankcase into two parts with the special tool. % 09920-13120: Crankcase separator...
Page 60 ENGINE 3-21 • Remove the crankshaft. • Remove the gearshift fork shafts and gearshift forks. • Remove the transmission. SECONDARY DRIVE BEVEL GEAR • Remove the over driving gear 1 and bush 2. • Remove the secondary drive bevel gear assembly.
Page 61: Engine Components Inspection And Servicing
(0.4724 – 0.4731 in) % 09900-20605: Dial calipers REASSEMBLY • Apply SUZUKI MOLY PASTE to the rocker arms and their shafts. ' 99000-25140: SUZUKI MOLY PASTE ( Rocker arm shaft: 27 N . m (2.7 kgf . m, 19.5 lb-ft)
Page 62 To properly measure the oi clearance with plastigauge, all gas- ket material must be removed from fitting surfaces of cylinder head and cover. Do not apply SUZUKI BOND “1216B” until after the oil clearance has been determined. • Tighten the cylinder head cover bolts evenly and diagonally to the specified torque.
Page 63 3-24 ENGINE If the camshaft journal oil clearance measured exceeds the limit, measure the outside diameter of camshaft. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. " Camshaft journal O.D. (Sprocket side) : 24.959 – 24.980 mm (0.9826 –...
Page 64: Cylinder Head
ENGINE 3-25 CYLINDER HEAD VALVE AND VALVE SPRING DISASSEMBLY • Using special tools, compress the valve springs and remove the two cotter halves 1 from valve stem. % 09916-14510: Valve spring compressor 09916-14910: Valve spring compressor attachment 09916-84511: Tweezers • Remove the valve spring retainer, inner spring and outer spring. •...
Page 65 3-26 ENGINE VALVE STEM RUNOUT Support the valve with “V” blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. " Valve stem runout Service Limit: 0.05 mm (0.002 in) % 09900-20701: Magnetic stand 09900-20606: Dial gauge (1/100 mm) 09900-21304: V-block...
Page 66 ENGINE 3-27 VALVE GUIDE SERVICING • Using the valve guide remover, drive the valve guide out to- ward the intake or exhaust rocker arm side. % 09916-44910: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
Page 67 3-28 ENGINE VALVE SEAT WIDTH • Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
Page 68 ENGINE 3-29 • Insert the solid pilot 1 (09916-24450: N-100-5.52) with a slight rotation. Seat the pilot snugly. Install the 45° cutter, attachment and T-handle. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
Page 69 3-30 ENGINE BOTTOM NARROWING CUT • If the contact area W is too wide or too low, use the 60° (intake side only) to narrow and raise the contact area. 60˚ (Intake only) FINAL SEAT CUT Contact area too low and too •...
Page 70 ENGINE 3-31 VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit.
Page 71 3-32 ENGINE • Insert the valves, with their stems coated with high quality mo- lybdenum disulfide lubricant (SUZUKI MOLY PASTE) all around and along the full stem length without any break. ' 99000-25140: SUZUKI MOLY PASTE & When inserting each valve, take care not to damage the lip of the stem seal.
Page 72: Piston Diameter
Service Limit: 83.085 mm (3.2711 in) % 09900-20508: Cylinder gauge set NOTE: When installing the water union to the cylinder, apply grease to the new O-rings. # 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig.
Page 73: Piston Ring Groove Width
3-34 ENGINE PISTON-TO-CYLINDER CLEARANCE As a result of the aforesaid measurement, if the piston to cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. " Piston to cylinder clearance Service Limit: 0.12 mm (0.0047 in) Piston oversize: 0.5, 1.0 mm PISTON RING TO GROOVE CLEARANCE...
Page 74 ENGINE 3-35 Oversize piston ring The following two types of oversize piston rings are used. They bear the following identification numbers. SIZE 0.5 mm O.S. 0.5 mm O.S. 1.0 mm O.S. Oversize oil ring The following two types of oversize oil rings are available as op- 1.0 mm O.S.
Page 75 3-36 ENGINE PISTON RING REASSEMBLY • Install the piston rings in the order of oil ring, 2nd ring and 1st ring. • The first member to go into the oil ring groove is a spacer 1. After placing the spacer, fit the two side rails 2. NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way.
Page 76 ENGINE 3-37 CONROD/CRANKSHAFT CONROD SMALL END I.D. Using a small bore gauge, measure the conrod small end inside diameter. ! Conrod small end I.D. Service Limit: 20.040 mm (0.7890 in) " 09900-20602: Dial gauge (1/1000 mm, 1 mm) 09900-22403: Small bore gauge (18 – 35 mm) If the conrod small end inside diameter exceeds the above men- tioned limit, replace the conrod.
Page 77 3-38 ENGINE • Place plastigauge axially on the crank pin avoiding the oil hole, at TDC or BDC side as shown. • Tighten the bearing cap with two-step torque values. NOTE: When fitting the bearing cap to crank pin, be sure to discriminate between its two ends, I.D.
Page 78 ENGINE 3-39 Conrod I.D. specification Code 1 I.D. specification 44.000 – 44.006 mm (1.7323 – 1.7325 in) 44.006 – 44.012 mm (1.7325 – 1.7328 in) 44.012 – 44.018 mm (1.7328 – 1.7330 in) Crank pin O.D. specification Code 2 O.D. specification 40.994 –...
Page 79 1 first and press in the other end. • Apply molybdenum oil solution to the crank pin and bearing surface. % 99000-25140: SUZUKI MOLY PASTE • When mounting the conrod on the crankshaft, make sure that I.D. code 2 of the conrod faces rearward.
Page 80 ENGINE 3-41 • Measure the crankshaft journal bearing I.D. 1 by using the special tool. ! Crankshaft journal bearing I.D. 1 Standard: 48.000 – 48.015 mm (1.8898 – 1.8904 in) " 09900-20508: Cylinder gauge set If each crankshaft journal bearing I.D. is not within the standard range, replace them with new ones.
Page 81 3-42 ENGINE CRANKSHAFT THRUST CLEARANCE Install the crankshaft in the right crankcase half after installing the thrust shim on the crankshaft. NOTE: The oil grooved face A of thrust shim 1 is faced to crankshaft web side. • Place the thrust washer, camshaft drive sprocket and primary drive gear on the right end of the crankshaft and tighten pri- mary drive gear bolt to the specified torque.
Page 82 ENGINE 3-43 CLUTCH CLUTCH DRIVE AND DRIVEN PLATES NOTE: Wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one.
Page 83 3-44 ENGINE GENERATOR/SIGNAL GENERATOR/ STARTER CLUTCH GENERATOR STATOR AND SIGNAL GENERATOR STATOR INSPECTION&8-8, 19, 20 GENERATOR STATOR AND SIGNAL GENERATOR STATOR SERVICING When replacing the generator stator or signal generator stator, route the wire properly. STARTER CLUTCH INSPECTION Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement.
Page 84: Oil Pump
ENGINE 3-45 STARTER CLUTCH SERVICING • Hold the rotor with off-set wrench and remove the starter clutch securing bolts. • When fitting the one way clutch to the guide 1, position flange side A of one way clutch to the rotor side. •...
Page 85 3-46 ENGINE TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. 1 Driveshaft bolt 2 Over driving gear 3 1st driven gear 4 4th driven gear 5 3rd driven gear 6 Driveshaft 7 5th driven gear 8 2nd driven gear 9 Counter haft/1st drive gear 0 4th drive gear A 3rd drive gear...
Page 86 Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. % 99000-25140: SUZUKI MOLY PASTE * Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
Page 87 3-48 ENGINE When installing the 1st and 3rd driven gear bushings, align the bushing oil hole with the driveshaft oil hole. TRANSMISSION GEARS AND RELATED PARTS...
Page 88: Gearshift Fork
ENGINE 3-49 GEARSHIFT FORK GEARSHIFT FORK TO GROOVE CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.
Page 89 • Remove the oil sump filter. • Clean the oil sump filter using compressed air. • When installing the O-ring, apply grease to it. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) OIL PIPE •...
Page 90 ENGINE 3-51 • When installing the oil pipe, use the new O-rings. • Apply a small quantity of the THREAD LOCK “1342” to the oil pipe retainer bolts and tighten them securely. ) 99000-32050: THREAD LOCK “1342” OIL PRESSURE REGULATOR •...
Page 91 " 09913-70210: Bearing installer set OIL PRESSURE SWITCH • Remove the oil pressure switch. • When installing the switch, apply SUZUKI BOND “1207B”. # Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘1207B”...
Page 92: Engine Reassembly
ENGINE 3-53 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. SECONDARY DRIVE BEVEL GEAR •...
Page 93 Use the new O-ring to prevent oil leakage • Clean the mating surfaces of the lef and right crankcase halves. • Apply SUZUKI BOND “1207B” to the mating surface of the right crankcase. * 99104-31140: SUZUKI BOND ‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”...
Page 94 (For the others) • Clean the mating surfaces of the crankcase and the secondary gear case. • Apply SUZUKI BOND “1207B” to the mating surface of the sec- ondary gear case. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B” (For the others)
Page 95 3-56 ENGINE • Tighten the secondary gear case bolts to the specified torque. # Secondary gear case bolt (Initial): 15 N . m (1.5 kgf . m, 11.0 lb-ft) (Final) : 22 N . m (2.2 kgf . m, 16.0 lb-ft) NOTE: Fit the washer to the bolt A .
Page 96 ENGINE 3-57 • Install the new O-ring. • Install the water pump cover. NOTE: Fit the clamp to the bolt A . CAM CHAIN/CAM CHAIN TENSIONER • Install the cam chain tensioner and cam chain. # Cam chain tensioner bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) 1 For front cylinder 2 For rear cylinder NOTE:...
Page 97 3-58 ENGINE • Install the starter driven gear and the idle gear. • Install the new gasket and dowel pins. • Install the generator cover. NOTE: Fit the new gaskets to the bolts A . NEUTRAL SWITCH • Install the springs and switch contacts. •...
Page 98 ENGINE 3-59 OIL FILTER • Apply engine oil lightly to the gasket of the oil filter before in- stallation. • Install the oil filter turning it by hand until feeling that the filter gasket contacts the mounting surface. Then tighten it 2 turns using the oil filter wrench.
Page 99 3-60 ENGINE • Install the cam driven gear 1 after installing the springs, pins and gearshift pawls. • Install the cam guide and the pawl lifter. • Apply a small quantity of THREAD LOCK “1342” to the nuts. ) 99000-32050: THREAD LOCK “1342” •...
Page 100 ENGINE 3-61 • Install the oil pump driven gear and the circlip. " 09900-06107: Snap ring pliers CLUTCH • Install the spacer 1 and the thrust washer 2. • Engage the chain with the oil pump drive gear. • Install the primary driven gear assembly and engage the chain with the oil pump driven gear.
Page 101 3-62 ENGINE • Install the washer 1 and the clutch sleeve hub nut 2. NOTE: The convex side of the washer faces outside. • Tighten the clutch sleeve hub nut to the specified torque with the special tool. # Clutch sleeve hub nut: 60 N . m (6.0 kgf . m, 43.5 lb-ft) "...
Page 102 ENGINE 3-63 • Install the wave washer seat 1 and the wave washer 2. • Install the clutch drive plate No.2 A first. • Install the drive and driven plate one by one into the clutch sleeve hub. • Install the push rod. •...
Page 103 • Apply engine oil to the new O-ring and install the oil jets. PISTON • Apply a light coat of SUZUKI MOLY PASTE to the piston pins. % 99000-25140: SUZUKI MOLY PASTE • When installing the piston, the arrow mark on the piston head...
Page 104 " 09918-53810: Chain tensioner lock tool # Cam chain tension adjuster mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Coat SUZUKI BOND “1207B” lightly to the mating surfaces among the crankcase mating surfaces. * 99104-31140: SUZUKI BOND ‘‘1207B” (For USA) 99000-31140: SUZUKI BOND ‘‘1207B”...
Page 105 3-66 ENGINE CYLINDER HEAD • Install the cam chain guide. 1 For front cylinder 2 For rear cylinder • Fit the dowel pins and the new cylinder head gasket. Use a new gasket to prevent gas leakage. • Install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque.
Page 106 Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket. • Before installing the camshafts onto each cylinder head, apply SUZUKI MOLY PASTE onto the camshaft journals. Also, apply engine oil onto the camshaft journal holders. % 99000-25140: SUZUKI MOLY PASTE NOTE: The camshaft is identified by the embossed letters “F”...
Page 107 3-68 ENGINE • Align the arrow marks on the front and rear camshafts so it is parallel with the surface of the cylinder heads. NOTE: Arrow marks are located to forward. Front Rear (No. 1) cylinder he d • Engage the chains on the cam sprockets with the locating pin holes A as shown in the photograph.
Page 108 ENGINE 3-69 • Apply SUZUKI BOND “1216B” to the mating surface of the cyl- inder head cover. • Fit the camshaft end caps 1. • Apply grease to the O-ring 2 and install it. (Front cylinder only) 99000-31230: SUZUKI BOND “1216B”...
Page 109 FRONT REAR NOTE: * Before installing the bolt 1 , apply SUZUKI BOND “1207B” to the thread of the bolt. * Allen bolt: 2 * Stainlessbolt: 1 , 3 , 4 . * Fit the gasket to the bolt 5 .
Page 110 • Install the intake pipe. • Apply grease to the new O-ring and install the water outlet union. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Install the gasket and the breather cover.
Page 111 3-72 ENGINE • Install the PAIR pipes. • Install the head cover caps 1. • Install the spark plugs. " 09930-10121: Spark plug wrench set...
Page 112: Shaft Drive
SHAFT DRIVE SHAFT DRIVE CONTENTS...
Page 113 4-2 SHAFT DRIVE SECONDARY BEVEL GEARS CONSTRUCTION A Secondary drive gear shaft nut 1 Bush B Secondary drive bevel gear 2 Overdriving driven gear 3 Circlip bearing retainer bolt C Secondary driven bevel gear 4 Output cam dog 5 Damper spring bolt 6 Secondary bevel gear set 7 Shims (5 kinds)
Page 114 SHAFT DRIVE 4-3 0.05 – 0.32 mm Backlash (0.002 – 0.013 in) Standard clearance A: 1.00 mm (0.039 in) B: 1.00 mm (0.039 in) Adjust backlash by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-05A-0A0 0.30 mm (0.012 in)
Page 115 4-4 SHAFT DRIVE REMOVAL SECONDARY DRIVE BEVEL GEAR The crankcase must be separated to service the secondary drive bevel gear. The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal.
Page 116 SHAFT DRIVE 4-5 SECONDARY DRIVEN BEVEL GEAR • Remove the bearing stopper with the special tool. # 09921-21820: Bearing retainer wrench • Remove the oil seal. INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear...
Page 117 NOTE: * Hollow portion A of the secondary driven bevel gear assembly faces inside. * It is not necessary to apply SUZUKI BOND “1207B” to the matching surface at this stage. • Measure the backlash as follows. • Set-up a dial gauge as shown in photo.
Page 118 SHAFT DRIVE 4-7 • Adjust the dial gauge so that it touches the secondary drive bevel gear cam dog; hold the driven bevel gear securely, and turn the drive bevel gear in each direction, reading the total backlash on the dial gauge. % Secondary bevel gear backlash Standard: 0.05 –...
Page 119 4-8 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • Remove the drive bevel gear assembly from the crankcase. •...
Page 120 REASSEMBLY SECONDARY DRIVEN BEVEL GEAR • Apply grease to the lip of oil seal. & 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Tighten the bearing stopper to the specified torque with the special tool.
Page 121 4-10 SHAFT DRIVE FINAL BEVEL GEARS CONSTRUCTION ITEM kgf.m lb-ft 16.5 29.0 10.0 72.5 A Final gear case bolt 1 Oil seal D Stopper plate (2 kinds) B Final driven beve gear bearing 2 Final gear bearing case E Final drive gear bearing 3 O-ring F Final drive bevel gear retainer screw...
Page 122 SHAFT DRIVE 4-11 Standard clearance C: 1.00 mm (0.039 in) Shim 3 size table Part number Thickness Standard clearance A: 1.00 mm (0.039 in) 27327-34200 0.35 mm (0.014 in) Shim 1 size table 27327-34210 0.40 mm (0.016 in) 27327-34220 0.50 mm (0.020 in) Part number Thickness 27327-34230...
Page 123 4-12 SHAFT DRIVE FINAL GEAR CASE REMOVAL After draining final gear oil, the following components must be removed in the described order before removing the final gear case. NOTE: Refer to the following pages for the details of each step. •...
Page 124 SHAFT DRIVE 4-13 1 Spring 2 Propeller shaft 3 Circlip • Using a chisel, unlock the nut. • Remove the final drive bevel gear coupling nut with the special tool. # 09924-62430: 22 mm Long socket 09924-64510: Final drive gear coupling holder •...
Page 125 4-14 SHAFT DRIVE • Remove the bearing from the final drive bevel gear with the bearing puller. The removed bearing must be replaced with a new one. NOTE: If no abnormal noise, the bearing removal is not necessary. • Remove the final gear bearing case bolts. •...
Page 126 SHAFT DRIVE 4-15 • Remove the bearing retainer screws, using an impact driver set. # 09900-09004: Impact driver set • Remove the final driven gear bearing and oil seal with the spe- cial tools. # 09941-64511: Bearing remover 09930-30102: Sliding shaft The removed bearing and oil seal must be replaced with new ones.
Page 127 ! Final gear case bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) NOTE: It is not necessary to apply SUZUKI BOND “1207B” to the match- ing surface at this stage. • Measure the clearance between the shims and bearing. If it is not within the specification, the shims must be changed.
Page 128 SHAFT DRIVE 4-17 If the backlash is not within the specification, adjust the shim thick- ness as follows: • Remove shims from final gear bearing case and final gear case, and measure total thickness. • In order not to change the clearance between final driven bevel gear and bearing, the total thickness of the shims installed af- ter a change is made must equal the original total thickness of shims.
Page 129 4-18 SHAFT DRIVE TOOTH CONTACT 1 INCORRECT (Contact at tooth top) After backlash adjustment is carried out, the tooth contact must be checked. • Remove the bolts from the final gear bearing case, and remove the case with the two 5 mm screws. ("4-14) Do not mis- place the shims.
Page 130 SHAFT DRIVE 4-19 FINAL GEAR CASE REASSEMBLY Reassemble the final gear case in the reverse order of disassem- bly. Pay attention to the following points. • Install a new oil seal 1 and O-ring 2 to the bearing stopper. Use new O-ring and oil seat to prevent oil leakage. •...
Page 131 4-20 SHAFT DRIVE • Install the needle roller bearing for the final driven bevel gear into the final gear case with the special tool. # 09913-76010: Bearing installer NOTE: The stamped ward on the bearing end should face to the driven bevel gear side.
Page 132 SHAFT DRIVE 4-21 • Apply SUZUKI BOND “1207B” to the mating surface of the final gear case and final gear bearing case. Do not block the breather passage when applying SUZUKI BOND “1207B”. ( 99000-31140: SUZUKI BOND “1207B” • Apply THREAD LOCK “1342” to the final gear case bolts and tighten them to the specified torque.
Page 133 • Apply grease to the lip of the oil seal and install it to the final drive bevel gear coupling. Use a new oil seal to prevent oil leakage. & 99000-25030: SUZUKI SUPER GREASE ‘‘A’’ (For USA) 99000-25010: SUZUKI SUPER GREASE ‘‘A’’ (For the others)
Page 134: Final Gear Case Installation
SHAFT DRIVE 4-23 • Install the stopper plate. When installing the plate, fit the protrusion A of plate to the one of the bearing stopper grooves. NOTE: Two kinds of plates are available to lock the stopper at the proper position.
Page 135: Fuel And Lubrication System
FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM...
Page 136: Fuel Pump
5-2 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM The fuel pump is operated by a vacuum force which is supplied from the carburetor intake pipe. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.
Page 137 FUEL AND LUBRICATION SYSTEM 5-3 FUEL TANK/FUEL VALVE REMOVAL Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Remove the front seat. ("7-2) • Remove the speedometer. • Disconnect the speedometer coupler. Be careful not to scratch the fuel tank. •...
Page 138 5-4 FUEL AND LUBRICATION SYSTEM • Disconnect the fuel hose 1 and vacuum hose 2. • Remove the throttle stop screw. • Remove the fuel tank. • Remove the fuel valve. • Remove the fuel level gauge mounting bolts. • Remove the fuel level gauge 3. •...
Page 139 FUEL AND LUBRICATION SYSTEM 5-5 INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel filter with compressed air. Also check the fuel valve for cracks. REMOUNTING •...
Page 140 5-6 FUEL AND LUBRICATION SYSTEM * Gasket 3 must be replaced with new ones to prevent fuel leakage. * Tighten the fuel level gauge bolts evenly. NOTE: mark A on the fuel level gauge forward. Face 10 N . m (1 0 kgf m, 7.0 lb-ft) Fuel tank FUEL PUMP REMOVAL...
Page 141 FUEL AND LUBRICATION SYSTEM 5-7 • Disconnect the fuel hoses 1, 2 and vacuum hose 3. INSPECTION Gasoline is highly flammable and explosive. Keep heat, sparks, and flames away from gasoline. • Disconnect the fuel hose 1, connect the suitable hose and insert the free end of the hose into a receptacle.
Page 142 5-8 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap A Throttle stop screw 2 Spring B Pilot screw 3 Jet needle stopper C Float 4 O-ring D Pilot jet 5 E-ring E Main jet holder 6 Jet needle F Main jet 7 Diaphragm/Piston valve G Needle valve 8 Funnel...
Page 143 FUEL AND LUBRICATION SYSTEM 5-9 SPECIFICATIONS SPECIFICATION ITEM E-02, 19, 24 E-03, 28 E-33 ← ← Carburetor type MIKUNI BDSR34 ← ← Bore size 34 mm I.D. No. 41F1 41F2 41F3 ← ← Idle r/min. 1 100 ± 100 r/min. Fuel level —...
Page 144: Diaphragm And Piston Operation
5-10 FUEL AND LUBRICATION SYSTEM DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the venturi A.
Page 145: Slow System
FUEL AND LUBRICATION SYSTEM 5-11 SLOW SYSTEM This system supplies fuel to the engine during engine operation with throttle valve 1 closed or slight opened. The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through #1 pilot air jet 4 and #2 pilot air jet 5.
Page 146: Main System
5-12 FUEL AND LUBRICATION SYSTEM MAIN SYSTEM As the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve 2 moves upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel passes around main air bleed pipe 5, mixes with the air admitted through main air jet 6 to from an emulsion and emulsion fuel enters needle jet 7.
Page 147: Float System
FUEL AND LUBRICATION SYSTEM 5-13 STARTER (ENRICHER) SYSTEM Pulling the starter (enricher) plunger 1 causes fuel to be drawn into the starter circuit from the float chamber The starter jet 3 meters this fuel. The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2.
Page 148: Accelerator Pump System
5-14 FUEL AND LUBRICATION SYSTEM ACCELERATOR PUMP SYSTEM This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve) is slow and sucking volume of fuel is less.
Page 149 FUEL AND LUBRICATION SYSTEM 5-15 REMOVAL • Remove the fuel tank. ("5-3) • Loosen the air intake pipe clamp screws. • Disconnect the breather hose. • Move the air inlet pipe to forward. • Remove the throttle cables 1. • Disconnect the throttle position sensor coupler 2. •...
Page 150 5-16 FUEL AND LUBRICATION SYSTEM • Loosen the clamp screw and remove the carburetor. • Remove the starter plunger. DISASSEMBLY • Remove the carburetor top cap 1. • Remove the spring 2 and piston valve 3 along with diaphragm • Pull out the jet needle holder 5.
Page 151 FUEL AND LUBRICATION SYSTEM 5-17 • Remove the spring 1, washers 2, 3, retainer 4 and jet needle • Remove the float chamber 6. $ 09900-09004: Impact driver set • Remove the accelerator pump plunger 7. • Remove the O-ring 8. Use a new O-ring to prevent fuel leakage.
Page 152 5-18 FUEL AND LUBRICATION SYSTEM • Use a %” size drill bit with a drill-stop to remove the pilot screw plug. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug.
Page 153 FUEL AND LUBRICATION SYSTEM 5-19 • Remove the casting valve cover. • Remove the casting valve 1 and the spring 2.
Page 154: Carburetor Cleaning
5-20 FUEL AND LUBRICATION SYSTEM CARBURETOR CLEANING Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
Page 155 FUEL AND LUBRICATION SYSTEM 5-21 CARBURETOR HEATER INSPECTION (for E02, E19) • Disconnect the carburetor heater terminal lead wires. • Connect the positive + terminal of a 12V battery to the termi- nal of the carburetor heater and the battery negative - termi- nal to the terminal.
Page 156 5-22 FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT • Measure the float height A by using a calipers with the carbu- retor slanting at an angle of 45° (as shown in the right illustra- tion) and the float arm just contacting the needle valve. •...
Page 157: Reassembly And Reinstallation
Replace the O-ring A with a new one. • Apply grease to the O-ring and install the accelerating plunger. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” • Fit the seal rings securely to the float chamber and install the...
Page 158 • Align the protrusion C of the carbureto top cap with the O-ring STARTER PLUNGER Apply a small quantity of grease to the starter plunger O-ring. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-rings with new ones.
Page 159 FUEL AND LUBRICATION SYSTEM 5-25 THROTTLE POSITION SENSOR POSITIONING • Install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle posi- tion sensor. Ω 1 Ω Ω • Measure the resistance between the throttle position sensor terminals as shown in the illustration.
Page 160: Lubrication System Chart
5-26 FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM CHART ROCKER ARM SHAFT (EX.) ROCKER ARM SHAFT (EX.) CAMSHAFT R. JOURNAL CAMSHAFT L. JOURNAL CAM FACES CAM FACES (IN. & EX.) (IN. & EX.) VALVES AND VALVES AND SPRINGS (IN. & EX.) SPRINGS (IN.
Page 161 PAIR (AIR SUPPLY) SYSTEM 5-27 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...
Page 162 5-28 PAIR (AIR SUPPLY) SYSTEM PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES • Inspect the hoses for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR REED VAVLE • Remove the PAIR valve cover. • Inspect the reed valve for the carbon deposit. •...
Page 163: Cooling System
COOLING SYSTEM COOLING SYSTEM CONTENTS...
Page 164 6-2 COOLING SYSTEM ENGINE COOLANT At the time of manufacture, the cooling system is filled with a Anti-freeze Freezing point 50:50 mixture of distilled water and ethylene glycol anti-freeze. density This 50:50 mixture will provide the optimum corrosion protection –30°C (–24°F) and excellent heat protection, and will protect the cooling system –40°C (–44°F) from freezing at temperatures above –31°C (–24°F).
Page 165: Cooling Circuit Inspection
COOLING SYSTEM 6-3 RADIATOR AND WATER HOSE COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • Remove the fuel tank. (#5-3) • Remove the radiator cap 1 and connect the tester to the filler. "...
Page 166: Radiator Removal
6-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the fuel tank. (#5-3) • Remove the frame head covers 1. • Disconnect the water hoses. • Drain engine coolant. • Remove the radiator cover 2. • Remove the radiator mounting bolts. • Remove the radiator.
Page 167: Radiator Cap Inspection
COOLING SYSTEM 6-5 RADIATOR CAP INSPECTION • Fit the cap 1 to the radiator cap tester 2. • Build up pressure slowly by operating the tester. Make sure that the pressure build-up stops at 95–125 kPa (0.95–12.5 kgf/ , 13.5–17.8 psi) and that, with the tester held standstill, the cap is capable of holding that pressure for at least 10 seconds.
Page 168: Cooling Fan
6-6 COOLING SYSTEM COOLING FAN INSPECTION • Disconnect the cooling fan lead wire coupler 1. • Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. • The voltmeter is for making sure that the battery applies 12 volts to the motor.
Page 169 COOLING SYSTEM 6-7 INSTALLATION • Put the cooling fan between the down tube and the engine. • Tighten the down tube mounting bolts. (#3-9) • Tighten the cooling fan mounting bolts. • Install the radiator. (#6-5) COOLING FAN THERMO-SWITCH REMOVAL •...
Page 170 Do not allow the switch to touch the pan, or false read- ing will result. • Apply grease to the O-ring ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Tighten the engine coolant temperature switch to the specified torque.
Page 171 COOLING SYSTEM 6-9 THERMOSTAT REMOVAL • Drain engine coolant. (#2-13) • Remove the secondary gear case cover. • Remove the reserve tank 1 and water hose 2. • Remove the water pump case. • Remove the thermostat case. • Remove the thermostat. INSPECTION Inspect the thermostat pellet for signs of cracking.
Page 172: Water Pump
6-10 COOLING SYSTEM • Keep on heating the water to raise its temperature. • Just when the water temperature reaches specified value, the Valve lift thermostat valve should have lifted by at least 6.0 mm (0.24 in). $ Thermostat valve lift Standard: Over 6.0 mm at 90°C (Over 0.24 in at 194°F) •...
Page 173 COOLING SYSTEM 6-11 • Remove the pin 1 and draw out the impeller shaft 2. • Remove the mechanical seal ring 3 and rubber seal 4. • Remove the bearing with the special tool. & 09921-20220: Bearing remover set NOTE: If no abnormal noise, bearing removal is not necessary.
Page 174: Reassembly And Installation
• Install the oil seal. NOTE: The stamped mark on the oil seal faces outside. • Apply a small quantity of the SUZUKI SUPER GREASE “A” to the oil seal lip. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 175 COOLING SYSTEM 6-13 • Install the new mechanical seal with a suitable size socket wrench and the special tool. NOTE: The new mechanical seal has been applied the sealer A . & 09924-84521: Bearing installer • Install the new bearing with the special tool. &...
Page 176 6-14 COOLING SYSTEM • Apply grease to the O-ring. • Set the water pump shaft end A to the oil pump shaft B. ( 99000-25030: SUZUKI SUPER GREASE “A” (For USA) 99000-25010: SUZUKI SUPER GREASE “A” (For the others) • Install the water pump screws.
Page 177: Chassis
CHASSIS CHASSIS CONTENTS...
Page 178: Exterior Parts
7-2 CHASSIS EXTERIOR PARTS REMOVAL SEAT • Remove the rear seat by removing the bolts. Be careful not to scratch the rear fender. • Remove the rear seat grip band by removing the bolts. • Remove the seat. Be careful not to scratch the rear fender. FRAME COVER •...
Page 179 CHASSIS 7-3 REAR FENDER • Remove the seat. ("7-2) • Disconnect the coupler 1. • Remove the left or right side frame handle grip. • Remove the rear fender 2. Be careful not to scratch the rear fenders. NOTE: When installing the frame handle grip bolts, apply a small quan- tity of THREAD LOCK “1303”...
Page 180 7-4 CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle 2 Bearing (R) 3 Front wheel 4 Spacer 5 Bearing (L) 6 Brake disc 7 Spacer A Front axle B Brake disc mounting bolt N . m kgf . m ITEM lb-ft 47.0 16.5 Left...
Page 181 CHASSIS 7-5 REMOVAL AND DISASSEMBLY • Loosen the front axle pinch bolt 1. • Loosen the front axle 2 by using the special tool. % 09900-18710: Hexagon socket (12 mm) • Raise the front wheel off the ground with a jack or a wooden block.
Page 182 7-6 CHASSIS INSPECTION WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
Page 183 Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay special attention to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the bearings before in- stalling. For USA ' 99000-25030: SUZUKI SUPER GREASE “A”...
Page 184 7-8 CHASSIS SPEED SENSOR • Apply SUZUKI SUPER GREASE “A” to the speed sensor dust seal. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A” • Align the grooves 1 on the speed sensor with the lugs 2 on the wheel hub.
Page 185 CHASSIS 7-9 FRONT BRAKE CONSTRUCTION 1 Cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Brake hose 6 Caliper holder 7 Caliper 8 Pad set 9 Piston ITEM N·m kgf·m lb-ft 0 Piston and dust seal A Insulator A Master cylinder mounting bolt B Brake hose union bolt C Brake caliper mounting bolt * The brake system is illed with an glycol-based brake fluid, which is classified DOT 4.
Page 186: Brake Pad Replacement
7-10 CHASSIS BRAKE PAD REPLACEMENT • Remove the guide hook A. • Remove the brake caliper by removing the brake caliper mount- ing bolts. • Remove the pin 1. • Remove the pad pin 2. • Remove the brake pads 3. * Do not operate the brake lever during or afte br ke pad removal.
Page 187: Brake Fluid Replacement
CHASSIS 7-11 BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handlebar straight. • Remove the master cylinder reservoir cap and diaphragm. • Remove as much old brake fluid as possible. • Fill the reservoir with new brake fluid. * Specification and classification: DOT 4 •...
Page 188: Brake Caliper Inspection
7-12 CHASSIS • Remove the brake pads. ("7-10) • Remove the insulator. • Remove the brake caliper holder. • Remove the spring. • Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using compressed air.
Page 189: Brake Caliper Reassembly And Remounting
* Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. PISTON SEALS • Install the piston seals 1 and dust seals 2 as shown. BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder. + 99000-25100: SUZUKI SILICONE GREASE...
Page 190: Brake Disc Inspection
7-14 CHASSIS • Tighten the brake caliper mounting bolts 1, and brake hose union bolt 2 to the specified torque. $ Brake caliper mounting bolt: 39 N . m (3.9 kgf . m, 28 lb-ft) Brake hose union bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) •...
Page 191: Master Cylinder Removal And Disassembly
CHASSIS 7-15 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt on the mas- ter cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle.
Page 192: Master Cylinder Inspection
7-16 CHASSIS • Remove the piston assembly. MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one. PISTON AND RUBBER PARTS Inspect the piston surface, primary/secondary cup, and dust boo for any scratches, wear or damage.
Page 193 CHASSIS 7-17 • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • When remounting the master cylinder onto the handlebars, align the master cylinder holder’s mating surface 1 with the punch mark 2 on the handlebars and tighten the upper clamp bolt first.
Page 194 7-18 CHASSIS FRONT FORK CONSTRUCTION 1 O-ring 2 Front fork spring 3 Damper rod ring 4 Rebound spring 5 Damper rod 6 Inner tube cover 7 Rubber 8 Washer 9 Inner tube 0 Slide metal A Dust seal B Oil seal stopper ring C Oil seal D Oil seal retainer E Oil lock piece...
Page 195 CHASSIS 7-19 REMOVAL AND DISASSEMBLY • Remove the front wheel. ("7-5) • Remove the brake hose from the hose guide. • Remove the guide hook A. • Remove the front brake caliper by removing the bolts. • Remove the front fender by removing its mounting bolts. Be careful not to scratch the front fender.
Page 196 7-20 CHASSIS • Remove the front fork inner tube cover 1, washer 2 and rub- ber 3. • Remove the inner tube cover stopper 4 by loosening the bolt. • Remove the inner tube cover guide 5. • Remove the front fork spring stopper nut 6 and fork spring 7. % 09900-18720: Hexagon socket (14 mm) •...
Page 197 CHASSIS 7-21 • Remove the dust seal 1 and the oil seal stopper ring 2. • Remove the oil seal by slowly pulling out the inner tube. NOTE: Be careful not to damage the inner tube. The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork.
Page 198 • Install the oil lock piece 1, slide metals 2, oil seal retainer 3 and oil seal 4 onto the inner tube. NOTE: Apply grease to the oil seal 4 lip lightly before installing it. For USA ' 99000-25030: SUZUKI SUPER GREASE “A” For the other countries ' 99000-25010: SUZUKI SUPER GREASE “A”...
Page 199 CHASSIS 7-23 NOTE: When installing the oil lock piece, insert the tapered end A of oil lock piece into the inner tube. • Insert the inner tube into the outer tube and install the oil seal 1 using the special tool. % 09940-52861: Front fork oil seal installer •...
Page 200 7-24 CHASSIS FORK OIL • Pour the specified fork oil into the inner tube. Fork oil type: SUZUKI FORK OIL SS-08 (#10) or equivalent fork oil , 99000-99001-SS8: SUZUKI FORK OIL SS-08 & Front fork oil capacity (each leg): 412 ml (13.9/14.5 US/Imp oz)
Page 201 CHASSIS 7-25 • Install the inner tube cover 1, rubber 2 and washer 3. • Remount the front fork and tighten the front fork lower clamp bolts temporarily. NOTE: Install the inner tube A until it seets to the flange part B of the steering stem upper bracket.
Page 202 7-26 CHASSIS STEERING CONSTRUCTION 1 Handlebars 2 Handlebar balancer 3 Handlebar set bolt cap 4 Handlebar clamp/holder 5 Steering stem upper bracket 6 Steering stem nut 7 Dust seal 8 Steering stem upper bearing 9 Steering stem lower bearing 0 Steering stem A Fron fork upper cover B Head ight housing bracket A Handlebar set bolt...
Page 203 CHASSIS 7-27 • Disconnect the front brake light switch lead wires 1. • Remove the front brake master cylinder 2. • Remove the right handlebar balancer 3, the right handlebar switch 4 and the throttle grip 5. • Disconnect the clutch lever position switch lead wires 6. •...
Page 204 7-28 CHASSIS • Remove the steering stem head nut 1 and washer. • Remove the steering stem upper bracket 2 and the front fork upper cover 3. NOTE: Hold the front fork upper cover to prevent it from falling. • Remove the cable guide 4. •...
Page 205 CHASSIS 7-29 • Remove the front turn signal light bracket. • Disconnect the front turn signal light lead-wire connector. • Remove the brake hose guide. • Remove the brake hose and speedo sensor lead-wire. ("9- • Remove the head light housing. •...
Page 206 7-30 CHASSIS • Remove the dust seal 1. • Remove the steering stem upper bearing 2. • Remove the steering stem lower bearing 3. • Remove the handlebar holders 4 from the steering stem up- per bracket. • Remove the handlebar bushes by using the proper tool and special tools.
Page 207 CHASSIS 7-31 INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. * Handlebars distortion * Race wear and brinelling * Bearing wear or damage * Abnormal bearing noise * Distortion of the steering stem • Remove the steering stem lower bearing inner race by using a chisel.
Page 208 • Apply grease to the upper and lower bearings before remount- ing the steering stem. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the bearings inner race and the dust seal.
Page 209 CHASSIS 7-33 HANDLEBAR HOLDER • Install the handlebar holders and related parts to the steering stem head. • Tighten the handlebar holder nuts to the specified torque. $ Handlebar holder nut: 70 N . m (7.0 kgf . m, 50.5 lb-ft) STEERING STEM UPPER BRACKET •...
Page 210 • Install the handlebar set bolt cap. Forward • Apply grease to the throttle cable end For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the front brake master cylinder. ('7-17) $ Front master cylinder mounting bolt: 10 N .
Page 211: Steering Tension Adjustment
CHASSIS 7-35 Master cylinder Handlebar Upper clamp bolt Punched mark Clearance • Install the clutch lever holder with the punch mark A aligned with the clutch lever holder clamp as shown. $ Clutch lever holder clamp bolt: 10 N . m (1.0 kgf .
Page 212: Rear Wheel
7-36 CHASSIS REAR WHEEL CONSTRUCTION 1 Rear axle 2 Spacer (LH) 3 Lock washer 4 Driven joint stopper 5 Driven joint 6 Damper 7 O-ring 8 Bearing (LH) 9 Spacer 0 Bearing (RH) A Wheel rim B Brake shoe C Brake camshaft D Brake panel E Brake cam lever A Driven joint stopper bolt...
Page 213 CHASSIS 7-37 Left Right For E-03, E-28, E-33 N . m kgf . m ITEM lb-ft 0.73 A Rear axle nut B Brake cam lever nut 25.5 C Rear torque link nut (F) D Rear torque link nut (R) 18.0...
Page 214 7-38 CHASSIS REMOVAL • Remove the seat 1. ('7-2) • Remove the rear fender 2. ('7-3) NOTE: The rear fender removal is not necessary when the rear part of motorcycle can be lifted high enough to take the rear wheel out smoothly.
Page 215 CHASSIS 7-39 • Remove the rear swingarm left cover. • Remove the rear axle shaft. DISASSEMBLY • Flatten the lock washers. • Remove the fitting bolts, washers and plates. • Pull off the driven joint 1. • Remove the O-ring 1. •...
Page 216 Pay attention to the following points: WHEEL BEARING • Apply grease to the bearings before installation. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special ool.
Page 217 Apply grease to the O-ring and the final gear spline before install- ing the driven joint. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Apply THREAD LOCK SUPER “1303” to the thread of driven joint stopper bolts.
Page 218: Rear Brake
7-42 CHASSIS REAR BRAKE REMOVAL AND DISASSEMBLY • Remove the rear wheel. ('7-38) • Remove the rear brake panel. • Remove the brake shoes. • Remove the rear brake cam lever 1 and rear brake cam 2 by removing bolt. •...
Page 219 Replace the brake shoes as a set, otherwise braking per- formance will be adversely affected. REASSEMBLY AND REMOUNTING BRAKE CAMSHAFT • When installing the brake camshaft, apply SUZUKI SUPER GREASE “A” to the camshaft and cam face. For USA # 99000-25030: SUZUKI SUPER GREASE “A”...
Page 220: Rear Brake Rod
7-44 CHASSIS • Tighten the brake cam lever bolt to the specified torque. $ Brake cam lever nut: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Install the rear wheel. ('7-41) • Adjust the rear brake pedal free travel. ('2-16) REAR BRAKE ROD REMOVAL AND DISASSEMBLY •...
Page 221: Reassembly Remounting
• Apply grease to the rear brake link pivot bolt and tighten it to the specified torque. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” $ Rear brake link pivot bolt: 29 N m (2.9 kgf . m, 21 lb-ft) •...
Page 222 7-46 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Rear cushion rod 3 Spacer 4 Rear cushion lever bearing 5 Rear cushion lever 6 Swingarm pivot bearing 7 Swingarm bea ing 8 Swingarm 9 B ot A Rear shock absorber mounting nut B Rear cushion rod mounting nut C Rear cushion lever mounting nut D Rear swingarm pivot bolt lock nut...
Page 223 CHASSIS 7-47 Left Right 50 N m 5.0 kgf m 36 0 lb-f 1 mm 1 mm 78 N . m 7.8 kgf . m 56.5 lb-ft 1 mm 1 mm 100 N . m 10.0 kgf . m 100 N . m 72 5 lb-ft 10.0 kgf .
Page 224 7-48 CHASSIS REMOVAL • Remove the rear wheel. ('7-41) • Remove the final gear case with propeller shaft. • Remove the secondary gear case cover 1. • Remove the right frame lower cover 2, clutch rear cover 3. : hooked part •...
Page 225 CHASSIS 7-49 • Remove the cushion lever mounting bolt and nut. • Remove the shock absorber upper mounting bolt and nut. • Remove the right side swingarm pivot bolt lock nut 1. • Remove the left and right side swingarm pivot bolts 2. NOTE: Slightly loosen the cushion rod mounting nuts and the shock ab- sorber lower mounting nut before removing the swingarm to fa-...
Page 226 7-50 CHASSIS INSPECTION AND DISASSEMBLY SPACER • Remove spacer from swingarm. • Remove the spacers from the cushion lever. • Inspect the spacers for any flaws or other damage. If any de- fects are found, replace the spacers with new ones. SWINGARM BEARING Insert the spacer into swingarm cushion rod upper side bearing and check the play to move the spacer up and down.
Page 227 CHASSIS 7-51 CUSHION LEVER BEARING Insert the spacer into bearing and check the play to move the spacer up and down. If an excessive play is noted, replace the bearing with a new one. • Remove the cushion rod lower side bearing 1 by using the special tools.
Page 228 When installing the bearings, stamped mark of bearing must face outside. • Apply grease to the spacers and bearings For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” • Assemble the shock absorber, cushion lever and cushion rods onto the swingarm.
Page 229 • Install the swingarm assembly, its pivot bearings and bolts (1, NOTE: Apply grease to the swingarm pivot bearings. For USA # 99000-25030: SUZUKI SUPER GREASE “A” For the other countries # 99000-25010: SUZUKI SUPER GREASE “A” 1: For left side swingarm pivot bolt 2: For right side swingarm pivot bolt •...
Page 230 $ Cushion lever mounting nut: 78 N . m (7.8 kgf . m, 56.5 lb-ft) FINAL GEAR CASE • Install the plate to the final gear case 1. Apply SUZUKI BOND “1207B” to the mating surface of swingarm and final gear case For USA * 99104-31140: SUZUKI BOND ‘‘1207B”...
Page 231 CHASSIS 7-55 NOTE: To install the final gear case easily, move the dust boot front and the universal joint back. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven bevel gear shaft. •...
Page 233: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS...
Page 234: Cautions In Servicing
8-2 ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.
Page 235: Connecting The Battery
ELECTRICAL SYSTEM 8-3 BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water re- plenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
Page 236 8-4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Ignition switch 5 Cooling fan 2 Ignition coil #2 6 Cooling fan thermo-switch 3 Fuel level gauge 7 Speedometer sensor 4 Rear brake switch...
Page 237 ELECTRICAL SYSTEM 8-5 F Oil pressure switch 8 Ignition coil #1 G Generator 9 Throttle position sensor H Gear position switch 0 Starter relay/main fuse I Side-stand switch A Battery J Fuse box B Ignitor K Turn signal side-stand relay C Engine coolant temperature sensor L Regulator/rectifier D Horn...
Page 238: Charging System
8-6 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator / rectifier Ig.switch Generator Fuse TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. are installed amounts of electricity. No accessories Check the battery for current Current leaks • Short circuit of wire harness leaks.
Page 239 ELECTRICAL SYSTEM 8-7 Measure the generator no-load voltage. (! 8-8) Incorrect • Faulty generator Correct Inspect the regulator/rectifier. Incorrect • Faulty regulator/rectifier (! 8-9) Correct Inspect wirings. Incorrect • Short circuit of wire harness Poor contact of couplers Correct • Faulty battery Others Battery overcharge •...
Page 240 8-8 ELECTRICAL SYSTEM REGULATED VOLTAGE • Remove the two seats. (!7-2) • Start the engine and keep it running at 5 000 r/min. with light- ing switch turned ON (except for E-03, 28, 24, 33 models) and dimmer switch turned HI position. Measure the DC voltage between the + and - battery termi- nals using the multi circuit tester.
Page 241 ELECTRICAL SYSTEM 8-9 REGULATOR/RECTIFIER • Remove the secondary gear case cover. • Disconnect the regulator/rectifier couplers. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified valve, replace the regulator/rectifier with a new one.
Page 242 8-10 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine stop Ignition switch switch To ignition Fuse(30A) coils and ignitor Starter motor Fuse Gear position Clutch lever (15A) witch position switch Starter relay Starter Turn signal/ button side-stand re ay side-stand switch TROUBLESHOOTING...
Page 243: Starter Motor Removal And Disassembly
ELECTRICAL SYSTEM 8-11 Check the starter relay. Incorrect • Faulty starter relay (! 8-13) Correct • Poor contact of the starter relay The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.
Page 244: Starter Motor Inspection
Reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • Apply grease to the lip of the oil seal. For U.S.A. - 99000-25030: SUZUKI SUPER GREASE “A” For the other countries - 99000-25010: SUZUKI SUPER GREASE “A”...
Page 245: Starter Relay Inspection
ELECTRICAL SYSTEM 8-13 • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. . 99000-25140: SUZUKI MOLY PASTE • Align the tonque 1 on the brush holder with the groove 2 on the housing end. • Align the threaded parts 3 on the housing end.
Page 246 8-14 ELECTRICAL SYSTEM Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. " 09900-25008: Multi circuit tester set # Starter relay resistance: 3 – 7 Ω Ω SIDE STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation.
Page 247 ELECTRICAL SYSTEM 8-15 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode. • Remove the secondary gear case cover. • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
Page 248 8-16 ELECTRICAL SYSTEM IGNITION SYSTEM Engine stop Side stand switch relay Ignition Fuse coil #2 Ignition switch ¹ Bl/W Ignitor Main Pickup gnition fuse coil coil #1 Generator Bl R/B G/Bl R Y B/Br Battery Gear Throttle position position switch sensor NOTE: The ignition cut-off circuit is incorporated in this ignitor to prevent over-running of engine.
Page 249 ELECTRICAL SYSTEM 8-17 Measure the battery voltage between input lead wires (O/W and B/W) at the ignitor with the ignition switch in the Incorrect • Faulty ignition switch “ON” position. • Faulty turn signal/side-stand relay • Faulty engine stop switch Correct •...
Page 250 8-18 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. (&5-3) • Disconnect the two spark plug caps. • Connect the new spark plugs to the each spark plug cap and ground them on the cylinder head. NOTE: Make sure that the each spark plug cap and spark plug are con- nected properly.
Page 251 ELECTRICAL SYSTEM 8-19 IGNITION COIL RESISTANCE • Remove the fuel tank. (&5-3) • Disconnect the ignition coil lead wires and plug caps. Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
Page 252 8-20 ELECTRICAL SYSTEM • Shift the transmission into the neutral, and then turn the igni- tion switch to the “ON” position. Ignitor Pickup coil coupler • Pull the clutch lever. coupler • Press the starter button and allow the engine to crank for a few seconds, and then measure the pickup coil peak voltage.
Page 253 ELECTRICAL SYSTEM 8-21 SPEEDOMETER REMOVAL • Remove the screws. • Disconnect the cover and couple . When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged. • Remove the speedometer.
Page 254 8-22 ELECTRICAL SYSTEM PARTS NAMES 1 High beam indicator light 2 Engine coolant temperature indicator light 3 Turn signal indicator light 4 Oil pressure indicator light 5 Neutral indicator light 6 Fuel level meter 7 Speedometer/tripmeter/clock 8 SELECT button 9 ADJUST button OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is set to ON, all LCD light up for three...
Page 255 ELECTRICAL SYSTEM 8-23 CLOCK • Displays the time (hours and minutes) on a 12-hour clock. • Setting the time. Hold down the ADJUST button for two seconds while pressing The setting that is the SELECT button and then flashing the hour display. flashing can be changed.
Page 256 8-24 ELECTRICAL SYSTEM INSPECTION ENGINE COOLANT TEMPERATURE INDICATOR LIGHT Engine coolant temperature sensor inspection: &6-8 • Remove the fuel tank. (&5-3) • Disconnect the engine coolant temperature sensor coupler. • Connect the jumper wire to the wire harness coupler. Check that the LED light immediately after turning the ignition switch on.
Page 257 ELECTRICAL SYSTEM 8-25 FUEL LEVEL METER • Remove the fuel tank. (&5-3) • Connect the speedometer. • Connect each resistor between the Yellow/Black and Black/ White lead wire at the wire harness. • Turn the ignition switch “ON” position and wait for approx, 13 seconds.
Page 258 • Install the O-ring and apply grease to it. For U.S.A. + 99000-25030: SUZUKI SUPER GREASE “A” For the other countries + 99000-25010: SUZUKI SUPER GREASE A” Use a new O-ring to prevent fuel leakage.
Page 259 ELECTRICAL SYSTEM 8-27 SPEED SENSOR INSPECTION If the speedometer, odometer or tripmeter does not function prop- erly. Inspect the speed sensor and connection of couplers. If the speed sensor and connection is all right, replace the unit with a new one. •...
Page 260 8-28 ELECTRICAL SYSTEM LAMPS HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W ....For E-03, 24, 28, 33 12 V 60/55 W + 4 W ..For E-02,19 For E-02, 19 BRAKE LIGHT/TAILLIGHT 12 V 21/5 W TURN SIGNAL LIGHT Front 12 V 21/5 W ..
Page 261: Starter Relay
ELECTRICAL SYSTEM 8-29 RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. INSPECTION Before removing the turn signal/side-stand relay, check the op- eration of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
Page 262 8-30 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any STARTER BUTTON abnormality is found, replace the respective switch Color Position assemblies with new ones. IGNITION SWITCH PUSH (For E-24) HORN BUTTON Color Color Position B/Bl Position PUSH LOCK FRONT BRAKE SWITCH...
Page 263: Initial Charging
ELECTRICAL SYSTEM 8-31 BATTERY SPECIFICATIONS Type designation FTX12-BS Capacity 12V, 36 kC (10 Ah)/10HR INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 which seals the battery filler holes 2. • Remove the caps 3 from the electrolyte container. NOTE: * Do not remove or pierce the sealed areas 4 of the electrolyte container.
Page 264 8-32 ELECTRICAL SYSTEM NOTE: If air bubbles do not rise from any one of the filler ports, tap the bottom of the electrolyte container two or three times. Never remove the electrolyte container from the battery while there is still electrolyte in the container. •...
Page 265: Recharging Operation
ELECTRICAL SYSTEM 8-33 RECHARGING OPERATION • Measure the battery voltage using the multi circuit tester. If the voltage reading is less than the 12.0V (DC), recharge the bat- tery with a battery charger. * When recharging the battery, remove the battery from the motorcycle.
Page 267: Servicing Information
SERVICING INFORMATION SERVICING INFORMATION CONTENTS...
Page 268 9-2 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder. Replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace.
Page 269 SERVICING INFORMATION 9-3 Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn camshaft. Replace. 4. Worn or burnt camshaft journal. Replace. Noise seems to come from the piston 1.
Page 270 9-4 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission jumps 1. Worn gear. Replace. out of gear. 2. Worn or distorted gearshift fork. Replace. 3. Weakened gearshift stopper spring. Replace. 4. Worn gearshift pawl. Replace. Engine idles poorly. 1. Valve clearance out of adjustment. Adjust.
Page 271 SERVICING INFORMATION 9-5 Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown. Clean. 2. Insufficient amount of engine oil. Check level and add. 3. Defective oil pump. Replace. 4. Clogged oil circuit. Clean. 5. Float chamber fuel level too low. Adjust float height.
Page 272 9-6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut. Adjust. Replace. 2. Broken bearing in steering stem. 3. Distorted steering stem. Replace. 4. Low tire pressure. Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks. Adjust or replace.
Page 273 SERVICING INFORMATION 9-7 BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi- 1. Leakage of brake fluid. Repair or replace. Replace. cient. 2. Worn brake pad/shoe. 3. Oil on brake pad surface. Clean brake disc and brake pads. 4. Worn brake disc. Replace.
Page 274 9-8 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. Replace. sparking. 2. Defective spark plug. 3. Defective pick-up coil. Replace. 4. Defective ignitor unit. Replace. Spark plug is wet or 1.
Page 275 SERVICING INFORMATION 9-9 BATTERY Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace. surfaces cell 2. Battery has been left in a run-down condition for a long Replace. plates. time. Battery runs down 1. Incorrect charging method. Check generator, regulator/ quickly.
Page 276 9-10 SERVICING INFORMATION WIRING DIAGRAM For E-03, -28, -33...
Page 277 SERVICING INFORMATION 9-11 For E-02, -19...
Page 278 9-12 SERVICING INFORMATION For E-24...
Page 279: Wire Harness Routing
SERVICING INFORMATION 9-13 WIRE HARNESS, CABLE AND HOSE ROUTING WIRE HARNESS ROUTING After clamping, cut the excessive end. 200 mm After clamping, cut Clamp the excessive end. Handlebar switch (L & R) Speed sensor Wiring harness Front turn signal light (L & R) Clamp Clamp Clutch cable...
Page 280 9-14 SERVICING INFORMATION Fuel level gauge lead wire Fuel pump & carburetor hose Wiring harness Fuel pump vacuum hose Install between wiring harness and fuel pump vacuum hose. Pass the battery -lead wire To spe dometer under the starter relay. Frame head cover (L &...
Page 281 SERVICING INFORMATION 9-15...
Page 282 9-16 SERVICING INFORMATION CABLE ROUTING Throttle cable Throttle cable Throttle plate (returning) cabl cable Clutch (pulling) cable Brake hose Throttle cable (pulling) Reservoir hose Guide High-tension cord Wiring harness Clutch cable Throttle cable clip Fuel hose Reservoir hose Clamp Clutch cable Starter cable Clamp...
Page 283: Fuel Hose Routing
SERVICING INFORMATION 9-17 FUEL HOSE ROUTING...
Page 284 9-18 SERVICING INFORMATION COOLING HOSE ROUTING...
Page 285 SERVICING INFORMATION 9-19 FRONT BRAKE HOSE ROUTING...
Page 286: Battery Protector
9-20 SERVICING INFORMATION BATTERY PROTECTOR Battery protector 60 mm 90 mm 90 mm 65 mm 30 mm 30 mm 0 mm Battery protector SPEED SENSOR LEAD WIRE ROUTING 30 mm Speed sensor lead wire clamp Speed sensor guide hook Speed sensor lead wire...
Page 287 SERVICING INFORMATION 9-21 SPECIAL TOOLS 09900-18710 09900-18720 09900-09004 Hexagon socket Hexagon socket 09900-06107 09900-06108 Impact driver set (12 mm) (14 mm) Snap ring pliers Snap ring pliers 09900-20102 09900-20202 09900-20203 09900 20204 09900-20205 Vernier calipers Micrometer Micrometer Micrometer Micrometer (200 mm) (25 –...
Page 288 9-22 SERVICING INFORMATION 09916-14910 09915-77330 09916-21111 09916-14510 Valve lifter Meter (For high 09916-10911 Valve seat cutter set Valve lifter attachment Valve lapper set pressure) 09916-34550 09916-22430 09916-34580 09916-44910 09916-44920 Valve guide reamer Valve seat cutter Valve guide reamer Valve guide Valve guide installer (N-128) (5.5 mm)
Page 289 SERVICING INFORMATION 9-23 09940-14911 09940-52861 Steering stem nut 09940-34520 09940-34531 Front fork oil seal 09940-92720 wrench T handle Attachment “A” installer Spring scale 09941-34513 09941-54911 09941-74911 09941- 4511 Steering outer race 09941-50111 Bearing outer race Steering bearing Bearing remover installer Bearing remover set remover installer...
Page 290 9-24 SERVICING INFORMATION TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Rocker arm shaft 19.5 Cylinder head cover bolt 6 mm 8 mm 18.0 Cylinder head bolt and nut Initial 8 mm Final 18.0 Initial 18.0 10 mm Final 27.5 Cam sprocket bolt...
Page 291: Secondary And Final
SERVICING INFORMATION 9-25 N . m kgf . m ITEM lb-ft Oil plug 6 mm 8 mm 13.0 10 mm 11.0 14 mm 16.5 16 mm 25.5 Engine mounting bolt 57.0 Engine mounting bracket bolt 16.5 Frame mounting bolt/nut 8 mm 16.5 10 mm 36.0...
Page 292 9-26 SERVICING INFORMATION CHASSIS N . m kgf . m ITEM lb-ft 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 lower clamp bolt 24.0...
Page 293 SERVICING INFORMATION 9-27 TIGHTENING TORQUE CHART For other bolts and nuts listed previously, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N . m kgf . m N . m kgf . m lb-ft lb-ft 0.15...
Page 294 9-28 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.18) ——— (1.02) Valve clearance 0.08 – 0.13 ——— (when cold) (0.003 – 0.005) 0.17 – 0.22 ——— (0.007 – 0.009) Valve guide to valve stem 0.010 –...
Page 295 SERVICING INFORMATION 9-29 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT 35.95 – 35.99 Cam height 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 36.58 –...
Page 296 9-30 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring free end gap Approx. (0.38) (0.30) 11.8 Approx. (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 groove clearance 0.180 ———...
Page 297 SERVICING INFORMATION 9-31 OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) Below 650 kPa (6.5 kgf/cm , 92 psi) ——— at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –...
Page 298 9-32 SERVICING INFORMATION SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 ——— (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side ——— (0.001 – 0.025) Damper spring free length 58.5 ———...
Page 299 SERVICING INFORMATION 9-33 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE 1 . 2 Firing order Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 –...
Page 300 540.6 (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 412 ml (each leg) (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster ———...
Page 301 SERVICING INFORMATION 9-35 TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front ——— (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear ——— (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front ———...
Page 303: Emission Control Information
EMISSION CONTROL INFORMATION 10-1 EMISSION CONTROL INFORMATION CONTENTS...
Page 304 The jet needle is also of special manufacture. Only one clip position is provided on the jet needle. If replace- ment becomes necessary the jet needle may only be replaced with an equivalent per orming replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best pos- sible performance and durability.
Page 305 EMISSION CONTROL INFORMATION 10-3 EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA MODEL ONLY) Fuel tank Fuel valve Carburetor surge control valve Canister Fuel pump Intake pipe PAIR valve PTC valve Carburetors...
Page 306: Evaporative Emission Control System Inspection
10-4 EMISSION CONTOROL INFORMATION CANISTER HOSE ROUTING 09404-06431 Clamp, air vent hose 13590-41F00 Air vent hose Valve comp, air vent 09401-09403 Clip, air vent valve hose Air vent hose 09355-40805 480 Hose, air vent valve vac 13595-41F00 Hose, air vent valve Air vent hose 13590-41F00 Valve comp, air vent...
Page 307 EMISSION CONTROL INFORMATION 10-5 CARBURETOR SURGE CONTROL VALVE • Remove the carbretor surge control valve. • Connect the vacuum pump to the vacuum port as shown. • Apply the specified negative pressure to the carburetor surge control valve. • The specified negative pressure must be maintained. •...
Page 308 10-6 EMISSION CONTOROL INFORMATION • Remove the vacuum pump and blow air through the air vent port A. • Air should flow through the carburetor surge control valve and out the canister port B. • Replace the carbretor surge control valve if air does not flow out the canister port B.
Page 309: Vl800K2 ('02- Model)
VL800K2 (’02-MODEL) 11-1 VL800K2 (’02-MODEL) CONTENTS SPECIFICATIONS ................11- 2 SERVICE DATA .................11- 4...
Page 310 11-2 VL800K2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 510 mm (98.818 in) Overall width ..............985 mm (38.779 in) Overall height ..............1 110 mm (43.700 in) Wheelbase ..............1 650 mm (64.960 in) Ground clearnce ............140 mm ( 5.511 in) Seat height ..............
Page 311 VL800K2 (’02-MODEL) 11-3 CHASSIS Front suspension ............Telescopic, coil spring, oil damped Rear suspension ............Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle .............. 38° (right & left) Caster ................33° 20’ Trail ................141 mm (3.55 in) Turning radius ...............
Page 312 11-4 VL800K2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.18) ——— (1.02) Valve clearance 0.08 – 0.13 ——— (when cold) (0.003 – 0.005) 0.17 – 0.22 ——— (0.007 – 0.009) Valve guide to valve stem 0.010 –...
Page 313 VL800K2 (’02-MODEL) 11-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT 35.95 – 35.99 Cam height 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 36.58 –...
Page 314 11-6 VL800K2 (’02-MODEL) ITEM STANDARD LIMIT Piston ring free end gap Approx. (0.38) (0.30) 11.8 Approx. (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 groove clearance 0.180 ———...
Page 315 VL800K2 (’02-MODEL) 11-7 OIL PUMP ITEM STANDARD LIMIT Oil pressure (at 60°C,140°F) Above 350 kPa (3.5 kgf/cm , 50 psi) Below 650 kPa (6.5 kgf/cm , 92 psi) ——— at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –...
Page 316 11-8 VL800K2 (’02-MODEL) SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 ——— (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side ——— (0.001 – 0.025) Damper spring free length 58.5 ———...
Page 317 VL800K2 (’02-MODEL) 11-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE 1 . 2 Firing order Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 –...
Page 318 540.6 (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 412 ml (each leg) (24.0 US oz, 25.0 lmp oz) Front fork spring adjuster ———...
Page 319 VL800K2 (’02-MODEL) 11-11 TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front ——— (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear ——— (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front ———...
Page 321 VL800K3 (’03-MODEL) 12- 1 VL800K3 (’03-MODEL) This chapter describes service data, service specifications and servicing procedures which dif- fer from those of the VL800K2 (’02-MODEL). NOTE: * Please refer to the chapter 1 through 11 for details which are not given in this chapter. CONTENTS SPECIFICATIONS .............
Page 322 12-2 VL800K3 (’03-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............2 510 mm (98.8 in) Overall width ............985 mm (38.7 in) Overall height............1 100 mm (43.3 in) Wheelbase ............1 655 mm (65.2 in) Ground clearnce ..........140 mm ( 5.5 in) Seat height............
Page 323: Table Of Contents
VL800K3 (’03-MODEL) 12-3 CHASSIS Front suspension..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped, spring pre-load 7-way adjustable Steering angle ............. 38° (right & left) Caster..............33° 20’ Trail ..............141 mm (3.55 in) Turning radius .............
Page 324 12-4 VL800K3 (’03-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance 0.08 – 0.13 — (when cold) (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –...
Page 325 VL800K3 (’03-MODEL) 12-5 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 36.58 –...
Page 326 12-6 VL800K3 (’03-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 groove clearance 0.180 —...
Page 327 VL800K3 (’03-MODEL) 12-7 OIL PUMP ITEM STANDARD LIMIT 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) at 3 000 r/min. CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –...
Page 328 12-8 VL800K3 (’03-MODEL) SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side — (0.001 – 0.025) Damper spring free length 58.5 —...
Page 329 VL800K3 (’03-MODEL) 12-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 – 6 Ω Primary Terminal Plug cap –...
Page 330: Brake Light/Taillight
(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 US oz, 25.0 lmp oz) Front fork spring adjuster —...
Page 331 VL800K3 (’03-MODEL) 12-11 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal free travel 20 – 30 — (0.8 – 1.2) Rear brake pedal height 75 – 85 — (3.0 – 3.3) Brake drum I.D. 180.7 Rear —...
Page 332 12-12 VL800K3 (’03-MODEL) FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump R + M octane or 91 octane ( ) 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 corro-...
Page 333 VL800K3 (’03-MODEL) 12-13 WIRING DIAGRAM For E-02, 19...
Page 334 12-14 VL800K3 (’03-MODEL) For E-03, 28, 33...
Page 335 VL800K3 (’03-MODEL) 12-15 For E-24...
Page 337 VL800K4 (’04-MODEL) 13- 1 VL800K4 (’04-MODEL) This chapter describes servicing procedures which differ from those of the VL800K3 (’03-MODEL). NOTE: * Please refer to the chapters 1 through 12 for details which are not given in his chapter. CONTENTS SPECIFICATIONS ................... 13- 2 SERVICE DATA ............
Page 338: Specifications
13-2 VL800K4 (’04-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 510 mm (98.8 in) Overall width ..................985 mm (38.8 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 339: Service Data
VL800K4 (’04-MODEL) 13-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve clearance 0.08 – 0.13 — (when cold) (0.003 – 0.005) 0.17 – 0.22 — (0.007 – 0.009) Valve guide to valve stem clear- 0.010 –...
Page 340 13-4 VL800K4 (’04-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 36.58 –...
Page 341 VL800K4 (’04-MODEL) 13-5 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 groove clearance 0.180 —...
Page 342 13-6 VL800K4 (’04-MODEL) OIL PUMP ITEM STANDARD LIMIT 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) at 3 000 r/min CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch cable play 10 –...
Page 343 VL800K4 (’04-MODEL) 13-7 SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side — (0.001 – 0.025) Damper spring free length 58.5 —...
Page 344 13-8 VL800K4 (’04-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug NGK: DPR7EA-9 Type DENSO: X22EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal – 2 – 6 Ω Primary Terminal Plug cap –...
Page 345 (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 US oz, 25.0 lmp oz) Front fork spring adjuster —...
Page 346 13-10 VL800K4 (’04-MODEL) TIRE Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Cold inflation tire pressure 200 kPa Front — (Solo riding) (2.00 kgf/cm , 29 psi) 250 kPa Rear — (2.50 kgf/cm , 36 psi) Cold inflation tire pressure 200 kPa Front —...
Page 347: Periodic Maintenance Chart
VL800K4 (’04-MODEL) 13-11 PERIODIC MAINTENANCE CHART Interval 1 000 6 000 12 000 18 000 24 000 miles 4 000 7 500 11 000 15 000 Item months Air cleaner element — Spark plugs — Valve clearance — — Engine oil Engine oil filter —...
Page 348: Cooling Hose Routing
13-12 VL800K4 (’04-MODEL) COOLING HOSE ROUTING...
Page 349: Rear Combination Light Installation
VL800K4 (’04-MODEL) 13-13 REAR COMBINATION LIGHT INSTALLATION Clamp Clamp Inside of the rear fender Rear fende...
Page 350 13-14 VL800K4 (’04-MODEL) WARNING DIAGRAM For E-03, 28, 33...
Page 351 VL800K4 (’04-MODEL) 13-15 For E-24...
Page 353: Vl800K5 ('05- Model)
CONTENTS SPECIFICATIONS ................... 14- 2 ABBREVIATIONS USED IN THIS MANUAL ..........14- 3 SAE-TO-FORMER SUZUKI TERM ............14- 5 SERVICE DATA..................14- 7 PERIODIC MAINTENANCE CHART ............14-17 PRECAUTIONS IN SERVICING ............... 14-18 FI SYSTEM TECHNICAL FEATURES .....
Page 354: Specifications
14-2 VL800K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 510 mm (98.8 in) Overall width ..................985 mm (38.8 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 355: Abbreviations Used In This Manual
VL800K5 (’05-MODEL) 14-3 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...
Page 356 : 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 357: Sae-To-Former Suzuki Term
14-5 SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM...
Page 358 14-6 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 359: Service Data
VL800K5 (’05-MODEL) 14-7 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 360 14-8 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 361 VL800K5 (’05-MODEL) 14-9 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 362 14-10 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 363 VL800K5 (’05-MODEL) 14-11 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 364 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 365 VL800K5 (’05-MODEL) 14-13 * 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 366 14-14 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 367 (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 368 14-16 VL800K5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion...
Page 369: Periodic Maintenance Chart
VL800K5 (’05-MODEL) 14-17 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 370: Precautions In Servicing
14-18 VL800K5 (’05-MODEL) PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a Click click is felt.
Page 371 VL800K5 (’05-MODEL) 14-19 • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
Page 372 14-20 VL800K5 (’05-MODEL) • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. 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 373: Electrical Circuit Inspection Procedure
VL800K5 (’05-MODEL) 14-21 ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
Page 374 14-22 VL800K5 (’05-MODEL) Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
Page 375 VL800K5 (’05-MODEL) 14-23 SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
Page 376 14-24 VL800K5 (’05-MODEL) USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. USING THE TESTER • Incorrectly connecting the + and - probes may cause the inside of the tester to burnout.
Page 377: Fi System Technical Features
VL800K5 (’05-MODEL) 14-25 FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
Page 378: Injection Stop Control
14-26 VL800K5 (’05-MODEL) COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE COOLANT TEMPERATURE SEN- When engine coolant temperature is low, injection time (vol- SOR SIGNAL ume) is increased.
Page 379: Fi System Parts Location
VL800K5 (’05-MODEL) 14-27 FI SYSTEM PARTS LOCATION A IAP sensor (Rear cylinder) F PAIR control solenoid valve B Ignition coil No.1 (Rear cylinder) G CKP sensor C ECT sensor H GP switch D Fuel injector (Rear cylinder) I FP relay E Fuel injector (Front cylinder)
Page 380 14-28 VL800K5 (’05-MODEL) J HO2 sensor N STP sensor K TO sensor O TP sensor L STVA P IAP sensor (Front cylinder) M Speedometer Q Ignition coil No.2 (Front cylinder)
Page 381: Fi System Wiring Diagram
VL800K5 (’05-MODEL) 14-29 FI SYSTEM WIRING DIAGRAM...
Page 382: User Mode
14-30 VL800K5 (’05-MODEL) SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared.
Page 383: Dealer Mode
VL800K5 (’05-MODEL) 14-31 DEALER MODE The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.
Page 384 14-32 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 385: Tps Adjustment
VL800K5 (’05-MODEL) 14-33 TPS ADJUSTMENT 1. Lift and support the fuel tank. ($14-93) 2. Adjust the engine rpm to 1 100 rpm. NOTE: Warm up the engine before adjustment. 3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness.
Page 386: Fail-Safe Function
14-34 VL800K5 (’05-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 760 “YES”...
Page 387: Fi System Troubleshooting
VL800K5 (’05-MODEL) 14-35 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.
Page 388: Visual Inspection
14-36 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 389 VL800K5 (’05-MODEL) 14-37 SELF-DIAGNOSTIC PROCEDURES NOTE: * Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in the memory. Such disconnection will erase the memorized information in ECM memory.
Page 390: Use Of Sds Diagnostic Procedures
14-38 VL800K5 (’05-MODEL) SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • If the malfunction code indicates (C00), the malfunction is cleared. • Disconnect the special tool from the dealer mode coupler. NOTE: * Even though the malfunction code (C00) is indicated, the previ- ous malfunction history code still remains stored in the ECM.
Page 391 VL800K5 (’05-MODEL) 14-39 USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
Page 392: Show Data When Trouble
14-40 VL800K5 (’05-MODEL) SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it 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 393 VL800K5 (’05-MODEL) 14-41 • Click “Show data when trouble” 1 to display the data. By clicking the drop down button 2, either “Failure #1” or “Failure #2” can be selected.
Page 394: Ecm Terminal
14-42 VL800K5 (’05-MODEL) ECM TERMINAL TERMINAL 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 395: Malfunction Code And Defective Condition
VL800K5 (’05-MODEL) 14-43 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 396 14-44 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 397 VL800K5 (’05-MODEL) 14-45 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 If lower than the above value, C31 P0705 (P0705) is indicated.
Page 398 14-46 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 399 VL800K5 (’05-MODEL) 14-47 5) Disconnect the CKP sensor coupler and measure the resis- tance. ! CKP sensor resistance: 184 – 276 Ω (Blue – Green) 6) Also, check the continuity between each terminal and ground. ! CKP sensor continuity: ∞ Ω (Infinity) (Blue –...
Page 400 14-48 VL800K5 (’05-MODEL) Step 2 1) Disconnect the CKP sensor coupler. 2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler. ! CKP sensor peak voltage: 4.0 V and more (+ Green –...
Page 401 VL800K5 (’05-MODEL) 14-49 “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 402 14-50 VL800K5 (’05-MODEL) Step 2 1) Connect the IAP sensor couplers and install the fuel tank. 2) Insert the needle pointed probes to the lead wire coupler. Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between G/B and B/Br wires or between G/W and B/Br wires).
Page 403 VL800K5 (’05-MODEL) 14-51 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. •...
Page 404 14-52 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 405 VL800K5 (’05-MODEL) 14-53 Step 1 (When indicating P0120-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
Page 406 14-54 VL800K5 (’05-MODEL) Step 1 (When indicating P0120-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the TP sensor coupler for loose or poor contacts. If OK, then check the TP sensor lead wire continuity. 4) Disconnect the TP sensor coupler.
Page 407 VL800K5 (’05-MODEL) 14-55 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the TP sensor coupler. 3) Check the continuity between Yellow wire and ground. ! TP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 4) If OK, then measure the TP sensor resistance at the termi- nals (between Yellow wire and Black wire).
Page 408 14-56 VL800K5 (’05-MODEL) Step 3 1) Connect the TP sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the TP sensor output voltage at the coupler (between + Bl/B wire and - B/Br wire) by turning the throttle grip.
Page 409 VL800K5 (’05-MODEL) 14-57 “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 410 14-58 VL800K5 (’05-MODEL) Step 1 (When indicating P0115-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler and ECM coupler.
Page 411 VL800K5 (’05-MODEL) 14-59 Step 1 (When indicating P0115-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. 4) Disconnect the ECT sensor coupler.
Page 412 14-60 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the ECT sensor resistance. ! ECT sensor resistance: Approx. 2.3 – 2.6 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 413 VL800K5 (’05-MODEL) 14-61 “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 414 14-62 VL800K5 (’05-MODEL) Step 1 (When indicating P0110-H:) 1) Remove the air cleaner box. ($14-103) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
Page 415 VL800K5 (’05-MODEL) 14-63 Step 1 (When indicating P0110-L:) 1) Remove the air cleaner box. ($14-103) 2) Turn the ignition switch OFF. 3) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
Page 416 14-64 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance. ! IAT sensor resistance: Approx. 2.6 kΩ at 20 °C (68 °F) (Terminal – Terminal) " 09900-25008: Multi-circuit tester set % Tester knob indication: Resistance (Ω) Is the resistance OK? •...
Page 417 VL800K5 (’05-MODEL) 14-65 “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 418 14-66 VL800K5 (’05-MODEL) Step 1 (When indicating P1651-H:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 419 VL800K5 (’05-MODEL) 14-67 Step 1 (When indicating P1651-L:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the TO sensor coupler for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
Page 420 14-68 VL800K5 (’05-MODEL) Step 2 1) Connect the TO sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage at the wire side coupler between Br/W and B/Br wires. ! TO sensor voltage: 0.4 –...
Page 421 VL800K5 (’05-MODEL) 14-69 “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 422 14-70 VL800K5 (’05-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA lead wire coupler. 3) Check the continuity between each wire terminal and ground. ! STVA continuity: ∞ Ω (Infinity) 4) If OK, then measure the STVA resistance. (between Black wire terminal and Pink wire terminal) and (between Green wire terminal and W/B wire terminal) ! STVA resistance: Approx.
Page 423 VL800K5 (’05-MODEL) 14-71 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from STVA, the function is normal.
Page 424 14-72 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 425 VL800K5 (’05-MODEL) 14-73 Step 1 (When indicating P1654-H:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
Page 426 14-74 VL800K5 (’05-MODEL) Step 1 (When indicating P1654-L:) 1) Remove the fuel tank. ($14-93) 2) Turn the ignition switch OFF. 3) Check the STP sensor coupler for loose or poor contacts. If OK, then check the STP sensor lead wire continuity. 4) Disconnect the STP sensor coupler.
Page 427 VL800K5 (’05-MODEL) 14-75 Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STP sensor coupler. 3) Check the continuity between Yellow wire terminal and ground. ! STP sensor continuity: ∞ Ω (Infinity) (Yellow – Ground) 6) If OK, then measure the STP sensor resistance at the coupler (between Yellow and Black wires).
Page 428 14-76 VL800K5 (’05-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Connect the STP sensor coupler. 3) Insert the needle pointed probes to the STP sensor coupler. 4) Disconnect the STVA lead wire coupler. 5) Turn the ignition switch ON. 6) Measure the STP sensor output voltage at the coupler (between + Y/W and - B/Br wires) when the secondary throttle valve is full closed and opened by moving the fast idle...
Page 429 VL800K5 (’05-MODEL) 14-77 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 430 14-78 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 431 VL800K5 (’05-MODEL) 14-79 5) Support the motorcycle with a jack. 6) Fold the side-stand to up position. 7) Make sure the engine stop switch is in the “RUN” position. 8) Insert the needle pointed probes to the lead wire coupler. 9) Turn the ignition switch ON.
Page 432 14-80 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 433 VL800K5 (’05-MODEL) 14-81 Step 2 1) Turn the ignition switch ON. 2) Measure the injector voltage between Y/R wire and ground. ! Injector voltage: Battery voltage (+ Y/R – - Ground) NOTE: Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.
Page 434 14-82 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 435 VL800K5 (’05-MODEL) 14-83 “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. •...
Page 436 14-84 VL800K5 (’05-MODEL) Step 2 1) Connect the PAIR control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the PAIR control solenoid valve coupler. 4) Measure the voltage at the wire side coupler between Black wire and ground.
Page 437 VL800K5 (’05-MODEL) 14-85 ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details) 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.
Page 438 14-86 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 439 VL800K5 (’05-MODEL) 14-87 4) Disconnect the HO2 sensor coupler and ECM coupler. 5) Check the continuity between W/Bl wire A and terminal 7. 6) Also, check the continuity between W/Bl wire A and ground. If sound of the continuity is not heard from the tester, the cir- cuit condition is OK.
Page 440 14-88 VL800K5 (’05-MODEL) Step 1 (When indicating C44/P0135:) 1) Remove the right frame cover. ($7-2) 2) Turn the ignition switch OFF. 3) Check the HO2 sensor coupler for loose or poor contacts. 4) Insert the needle pointed probes to the HO2 sensor coupler. 5) Turn the ignition switch ON and measure the heater voltage between W/B wire (ECM side) and ground.
Page 441 VL800K5 (’05-MODEL) 14-89 Step 2 (When indicating C44/P0135:) 1) Turn the ignition switch OFF. 2) Disconnect the HO2 sensor coupler. 3) Check the resistance between the terminals (White – White) of the HO2 sensor. ! HO2 heater resistance: 6.5 – 8.9 Ω (at 23 °C/73.4 °F) (White –...
Page 442: Sensors
14-90 VL800K5 (’05-MODEL) SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. ($14-46) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. ($3-18) • Install the generator cover in the reverse order of removal. IAP SENSOR INSPECTION The intake air pressure sensor is installed on the air intake pipe.
Page 443: Iat Sensor Inspection
VL800K5 (’05-MODEL) 14-91 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the back side of the air cleaner box. ($14-61) IAT SENSOR REMOVAL AND INSTALLATION • Remove the air cleaner box. ($14-103) • Remove the IAT sensor from the air cleaner box. •...
Page 444: Fuel Delivery System
14-92 VL800K5 (’05-MODEL) FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe (including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.
Page 445: Fuel System
VL800K5 (’05-MODEL) 14-93 FUEL SYSTEM FUEL TANK LIFT-UP • Remove the seat. ($7-2) • Remove the fuel tank mounting bolt 1. • Lift and support the fuel tank about 10 cm (3.94 in) with the prop stay. NOTE: Be careful not to lift the fuel tank more than about 10 cm (3.94 in), or hoses will be twisted.
Page 446: Fuel Pressure Inspection
14-94 VL800K5 (’05-MODEL) FUEL PRESSURE INSPECTION • Lift and support the fuel tank. ($14-93) • Place a rag under the fuel feed hose. • Remove the fuel feed hose 1. • Install the special tools between the fuel tank and fuel delivery pipe.
Page 447: Fuel Pump Inspection
VL800K5 (’05-MODEL) 14-95 FUEL PUMP INSPECTION Turn the ignition switch ON and check that the fuel pump oper- ates for few seconds. If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor.
Page 448: Fuel Pump Relay Inspection
14-96 VL800K5 (’05-MODEL) FUEL PUMP RELAY INSPECTION Fuel pump relay is located inside the secondary gear case cover. • Remove the secondary gear case cover. • Remove the fuel pump relay 1. First, check the insulation between A and B terminals with pocket tester.
Page 449 VL800K5 (’05-MODEL) 14-97 FUEL PUMP CONSTRUCTION 1 Fuel pump 4 Fuel mesh filter cover 2 Plate assy 5 Fuel feed hose ITEM N·m kgf-m lb-ft 3 Fuel mesh filter A Fuel pump mounting bolt...
Page 450: Fuel Pump Removal And Disassembly
14-98 VL800K5 (’05-MODEL) FUEL PUMP REMOVAL AND DISASSEMBLY • Remove the fuel tank. ($14-93) • Remove the fuel pump assembly 1 by removing its mounting bolts diagonally. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the fuel mesh filter cover 2. •...
Page 451: Fuel Mesh Filter Inspection And Cleaning
VL800K5 (’05-MODEL) 14-99 • Remove the fuel mesh filter 7 and rubber cushion 8. FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result. Blow the fuel mesh filter with compressed air.
Page 452 14-100 VL800K5 (’05-MODEL) FUEL PUMP REASSEMBLY AND INSTALLA- TION Install the fuel pump in the reverse order of removal and disas- sembly. Pay attention to the following points: • Install a new bushing 1 to the fuel pump. Use the new bushing to prevent fuel leakage.
Page 453 VL800K5 (’05-MODEL) 14-101 • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. , 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) The O-ring must be replaced with a new one to prevent fuel leakage.
Page 454: Throttle Body
14-102 VL800K5 (’05-MODEL) THROTTLE BODY CONSTRUCTION 1 STP sensor 9 Three way joint (only E33) 2 TP sensor 0 Hose (only E33) 3 IAP sensor A Vacuum hoses 4 STVA B Fast idle screw 5 Fuel delivery pipe C Throttle stop screw 6 O-ring A STP sensor mounting screw ITEM...
Page 455: Air Cleaner Box Removal
VL800K5 (’05-MODEL) 14-103 AIR CLEANER BOX REMOVAL • Remove the fuel tank. ($14-93) • Remove the bolts 1 and lossen the clamp screw 2. NOTE: “✩” indicates hook location. • Disconnect the IAT sensor lead wire coupler 3. • Disconnect the PAIR hose 4. •...
Page 456: Throttle Body Removal
14-104 VL800K5 (’05-MODEL) THROTTLE BODY REMOVAL • Remove the air intake pipe. ($14-103) • Disconnect the TP sensor lead wire coupler 1, STVA lead wire coupler 2 and STP sensor lead wire coupler 3. • Disconnect the fuel injector lead wire couplers 4. •...
Page 457: Throttle Body Disassembly
VL800K5 (’05-MODEL) 14-105 THROTTLE BODY DISASSEMBLY • Remove the vacuum hose 1 and fuel feed hose 2. • Remove the clamp 3. • Remove the fuel delivery hose 4. • Remove the fuel delivery pipes 5. • Remove the fuel injectors 6 •...
Page 458 14-106 VL800K5 (’05-MODEL) • Remove the STP sensor 8 with the special tool. " 09930-11950: Torx wrench NOTE: * Prior to disassembly, mark the STP sensor’s original position with a paint or scribe for accurate reinstallation. * TP sensor and STP sensor look very much alike. To avoid confusion, mark identifications when removing.
Page 459: Throttle Body Cleaning
VL800K5 (’05-MODEL) 14-107 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 460 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. ($14-118) , 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A”...
Page 461 VL800K5 (’05-MODEL) 14-109 • Install the O-ring and dust seal to each fuel injector. • Apply thin coat of the engine oil to the new O-ring and cushion seal. 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 462 14-110 VL800K5 (’05-MODEL) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the TP sensor lead wire coupler 1. TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.
Page 463: Fuel Injector Removal
VL800K5 (’05-MODEL) 14-111 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows: • Disconnect the STP sensor coupler. • Close the secondary throttle valve fully by moving the fast idle link, and measure the STP sensor resistance (between Yel- low wire terminal and Black wire terminal).
Page 464: Fuel Injector Inspection
14-112 VL800K5 (’05-MODEL) FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank. The fuel injector can be checked without removing it from the throttle body.
Page 465: Fast Idle
VL800K5 (’05-MODEL) 14-113 FAST IDLE The fast idle system is automatic type. When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed. When the engine has warmed up, depending on the water tem- perature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.
Page 466 14-114 VL800K5 (’05-MODEL) • Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened. Example: TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0.08 V STV fully open 1.20 V Idle...
Page 467 VL800K5 (’05-MODEL) 14-115 THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders. USE OF DIGITAL VACUUM TESTER Step 1 • Lift and support the fuel tank. (!14-93) • Start up the engine and run it in idling condition for warming up. •...
Page 468 14-116 VL800K5 (’05-MODEL) Step 3 • Turn in two idle air screws to the complete close position. • Check for difference of vacuum between front cylinder and rear cylinder. • Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.
Page 469 VL800K5 (’05-MODEL) 14-117 • Connect a tachometer. • Start up the engine and keep it running at 1 100 rpm by turn- ing throttle stop screw 2. 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 470 14-118 VL800K5 (’05-MODEL) THROTTLE POSITION SENSOR (TPS) SETTING After all adjustments are completed, check or adjust the TPS 1 setting condition.
Page 471: Emission Control Systems
14-119 EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VL800 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. 1 Fuel tank...
Page 472 14-120 VL800K5 (’05-MODEL) EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem (For E-02, -19, -24 and -33). The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve.
Page 473: Noise Emission Control System
VL800K5 (’05-MODEL) 14-121 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any 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 474: Pair (Air Supply) System And Emission Control System Inspection
14-122 VL800K5 (’05-MODEL) PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM INSPECTION PCV HOSE • Remove the PCV hose from the crankcase breather cover. • Inspect the PCV hose for wear or damage. • If it is worn or damaged, replace the PCV hose with a new one.
Page 475: Pair Control Solenoid Valve
VL800K5 (’05-MODEL) 14-123 PAIR CONTROL SOLENOID VALVE • Lift and support the fuel tank. ($14-93) • Remove the PAIR control solenoid valve cover 1. • Disconnect the PAIR control solenoid valve lead wire coupler • Disconnect the PAIR hoses. • Remove the PAIR control solenoid valve 3. •...
Page 476: Evaporative Emission Control System Inspection (Only For E-33)
14-124 VL800K5 (’05-MODEL) EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33) • Remove the seats 1. ($7-2) • Remove the speedometer 2. ($5-3) • Remove the fuel tank 3. ($14-93) • Remove the fuel frame cover 4. ($7-2) HOSES (EVAP hose) Inspect the hoses for wear or damage.
Page 477: Tightening Torque
VL800K5 (’05-MODEL) 14-125 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 478: Wiring Harness, Cable And Hose Routing
14-126 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 contr l solenoid valve leadwire Ignition oil leadwire To generator Clamp...
Page 479 VL800K5 (’05-MODEL) 14-127 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 480 14-128 VL800K5 (’05-MODEL)
Page 481 VL800K5 (’05-MODEL) 14-129 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 482: Cooling System Hose Routing
14-130 VL800K5 (’05-MODEL) COOLING SYSTEM HOSE ROUTING...
Page 483 VL800K5 (’05-MODEL) 14-131 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 484 14-132 VL800K5 (’05-MODEL) FUEL TANK INSTALLATION Cut the clamp Frame...
Page 485: Brake Pedal Installation
VL800K5 (’05-MODEL) 14-133 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 486: Pair (Air Supply) System Diagram
14-134 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 487: Pair (Air Supply) System Hose Routing
VL800K5 (’05-MODEL) 14-135 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 488: Evap Canister Hose Routing (Only For E-33)
14-136 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 489: Fuel Feed Hose Routing
VL800K5 (’05-MODEL) 14-137 FUEL FEED HOSE ROUTING 1 IAP sensor (Front cylinder) 2 IAP sensor (Rear cylinder) 3 PCV (Breather) hose 4 Fuel feed hose *1 Match mark (White)
Page 490: Special Tools
14-138 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 491 VL800K5 (’05-MODEL) 14-139 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...
Page 493: Vl800Tk5 ('05- Model)
VL800TK5 (’05-MODEL) 15- 1 VL800TK5 (’05-MODEL) This chapter describes service specifications, service data and servicing procedures which dif- fer from those of the VL800K5 (’05-MODEL). NOTE: * Any differences between the VL800K5 (’05-MODEL) and VL800TK5 (’05-MODEL) in specifi- cations and service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 14 for details which are not given in this chapter.
Page 494: Fuel System
15-2 VL800TK5 (’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 495 VL800TK5 (’05-MODEL) 15-3 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 clear- 0.010 –...
Page 496 15-4 VL800TK5 (’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 497 VL800TK5 (’05-MODEL) 15-5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –...
Page 498 15-6 VL800TK5 (’05-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.42 –...
Page 499 VL800TK5 (’05-MODEL) 15-7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — ECT sensor resistance 20 °C Approx.
Page 500 15-8 VL800TK5 (’05-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
Page 501: Battery
VL800TK5 (’05-MODEL) 15-9 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 – 4.0 mm (0.08 –...
Page 502: Position/Parking Light
15-10 VL800TK5 (’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 503 (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 504 15-12 VL800TK5 (’05-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
Page 505 VL800/TK6 ('06-MODEL) 16- 1 VL800/TK6 ('06-MODEL) This chapter describes service specifications, service data and servicing p ocedures which dif- fer from those of the VL800TK5 (’05-MODEL). NOTE:*Any differences between the VL800TK6 (’06-MODEL) and VL800TK5 (’05-MODEL) in specifications and service data are indicated with an asterisk mark (*).
Page 506: Specifications
16- 2 VL800/TK6 ('06-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................
Page 507: Service Data
VL800/TK6 ('06-MODEL) 16- 3 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 clear- 0.010 –...
Page 508 16- 4 VL800/TK6 ('06-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)
Page 509 VL800/TK6 ('06-MODEL) 16- 5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –...
Page 510 16- 6 VL800/TK6 ('06-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103)
Page 511 VL800/TK6 ('06-MODEL) 16- 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —...
Page 512 16- 8 VL800/TK6 ('06-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
Page 513 VL800/TK6 ('06-MODEL) 16- 9 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 514 16-10 VL800/TK6 ('06-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 515 (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 516: Special Tools
16-12 VL800/TK6 ('06-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...
Page 517: Conrod/Crankshaft
VL800/TK6 ('06-MODEL) 16-13 CONROD/CRANKSHAFT CRANKCASE/CRANKSHAFT BEARING INSPECTION • Inspect the crankshaft and crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. • Measure the crankshaft journal O.D. 1 by using the special tool.
Page 518 16-14 VL800/TK6 ('06-MODEL) Bearing thickness Color code Color (Part No.) Thickness Green 2.006 – 2.009 mm (12229-39G00-0A0) (0.0789 – 0.0790 in) Black 2.009 – 2.012 mm (12229-39G00-0B0) (0.0790 – 0.0792 in) Brown 2.012 – 2.015 mm (12229-39G00-0C0) (0.0792 – 0.0793 in) Bearing must be replaced as a set.
Page 519 VL800/TK6 ('06-MODEL) 16-15 NOTE: Bearing Using the hand-press is recommended to remove the crankshaft journal bearings. However, the crankshaft journal bearings can be removed by using with the following special tools. " 09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer •...
Page 520 16-16 VL800/TK6 ('06-MODEL) • Set the bearings installed in the special tool to the crankcase half as shown. * Be sure the bearing protruded side B faces the crankcase bore. * Align the special tool mating surface with the line mark C on the crankcase.
Page 521 VL800/TK6 ('06-MODEL) 16-17 NOTE: Using the hand-press is recommended to install the crankshaft journal bearings. However, the crankshaft journal bearings can be installed by using the following special tools. " 09924-84510: Bearing installer set 09924-74570: Final drive gear bearing remover/installer...
Page 522: Emission Control Systems
16-18 VL800/TK6 ('06-MODEL) EMISSION CONTROL SYSTEMS EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST sys- tem. The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve.
Page 523 This chapter describes service specifications, service data and servicing p ocedures which differ from those of the VL800TK6 ('06-MODEL). NOTE:*Any differences between the VL800TK6 ('06-MODEL) and VL800/TK7 ('07-MODEL) in specifications and service data are indicated with an asterisk mark (*).
Page 524: Fuel System
17- 2 VL800/TK7 ('07-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 510 mm (98.8 in) Overall width..................* 970 mm (38.2 in) Overall height ..................* 1 105 mm (43.5 in) Wheelbase ..................1 655 mm (65.2 in) Ground clearance................
Page 525 VL800/TK7 ('07-MODEL) 17- 3 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 clear- 0.010 –...
Page 526 17- 4 VL800/TK7 ('07-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)
Page 527 VL800/TK7 ('07-MODEL) 17- 5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –...
Page 528: Clutch
17- 6 VL800/TK7 ('07-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 turn back — Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103)
Page 529 VL800/TK7 ('07-MODEL) 17- 7 THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temper- Approx. 75 °C (167 °F) — ature Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —...
Page 530 17- 8 VL800/TK7 ('07-MODEL) FI SENORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE 184 – 276 Ω CKP sensor resistance CKP sensor peak voltage 4.0 V and more When cranking IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx.
Page 531: Mm (5.5 In)
VL800/TK7 ('07-MODEL) 17- 9 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 532: Brake Light/Taillight
17-10 VL800/TK7 ('07-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 533 (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 534 17-12 VL800/TK7 ('07-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...
Page 535: Fuel Pump And Fuel Level Gauge Removal
VL800/TK7 ('07-MODEL) 17-13 FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL REMOVAL • Remove the fuel tank. (!VL800K5-93) • Remove the fuel pump assembly 1 mounting bolts diago- nally. " Gasoline is highly flammable and explosive. Keep heat, spark and flame away.
Page 536: Fuel Pump And Fuel Level Gauge Installation
• Install the fuel level gauge 1 into the fuel tank. NOTE: Push the lock portion A fully until the clicking sound heard. • Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it. $ 99000-25010: SUZUKI SUPER GREASE “A”...
Page 537: Fuel Level Gauge Inspection
VL800/TK7 ('07-MODEL) 17-15 FUEL LEVEL GAUGE INSPECTION • Remove the fuel level gauge assembly. • Measure the resistance at each fuel level gauge float position. 19.5 If the resistance is incorrect, replace the fuel level gauge with (0.77 in) a new one.
Page 538: Cable Routing
17-16 VL800/TK7 ('07-MODEL) CABLE ROUTING Throttle cable No.2 Clamp the white tape of Throttle cable No.1 clutch cable to the center 0 mm of frame dent part. Clutch cable Handle switch RH harness Brake hose Outside High tension 0 mm...
Page 539: Front Brake Hose Routing
VL800/TK7 ('07-MODEL) 17-17 FRONT BRAKE HOSE ROUTING...
Page 540 ...
Page 541 VL800/C/ TK9 (’09-MODEL) NOTE: • Any differences between the VL800/C/TK8 (’08-model) and VL800/C/TK9 (’09-model) in specifications and service data are indicated with an asterisk mark (*). CONTENTS © COPYRIGHT SUZUKI MOTOR CORPORATION 2008...
Page 542 18-2 VL800/C/TK9 (’09-MODEL) VL800/C/ TK9 (’09-MODEL) CONTENTS THROTTLE BODY REASSEMBLY ............18-46 THROTTLE BODY INSTALLATION ............18-50 STP SENSOR ADJUSTMENT..............18-51 TP SENSOR ADJUSTMENT ..............18-52 ISC VALVE REMOVAL ................18-53 ISC VALVE INSTALLATION ..............18-53 ISC VALVE INSPECTION ..............
Page 543 VL800/C/TK9 (’09-MODEL) 18-3 ABBREVIATIONS USED IN THIS MANUAL NOTE: Please refer to the VL800 (’06-model) service manual and VL800/C/T (’07/’08-models) service informations for other abbreviations which are not given in this manual. EVAP : Evaporative Emission ISC Valve : Idle Speed Control Valve (ISCV)
Page 544 Turning radius ..................3.0 m (9.8 ft) Front brake ..................Disc brake Rear brake ..................Drum brake Front tire..................130/90-16 M/C 67H, tube type..VL800/T/UE 130/90-16 M/C 67H, tubeless ..VL800C/CUE Rear tire ..............
Page 545: Periodic Maintenance Schedule
VL800/C/TK9 (’09-MODEL) 18-5 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and months for your convenience.
Page 546 This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the VL800K6 (’06-MODEL). For details other than the following items, refer to the VL800 Service Manual. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months).
Page 547 VL800/C/TK9 (’09-MODEL) 18-7 • Remove the air cleaner element 6. • Carefully use compressed air to clean the air cleaner element.  Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the...
Page 548 18-8 VL800/C/TK9 (’09-MODEL) SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months) and replace every 12 000 km (7 500 miles, 24 months). No.2 (FRONT) SPARK PLUG REMOVAL (For E-02, 19, 24, 33) • Remove the air cleaner. (Page 18-6) •...
Page 549 VL800/C/TK9 (’09-MODEL) 18-9 • Place a rug on the cylinder head cap 2. • Open the cylinder head cover cap 2 as shown. • Disconnect the spark plug caps 3.  The hot engine can burn you. Wait until the engine are cool enough to touch.
Page 550 18-10 VL800/C/TK9 (’09-MODEL) SPARK PLUG GAP • Measure the plug gap with a thickness gauge. If out of specifi- cation, adjust it to the following gap.  09900-20803: Thickness gauge  Spark plug gap A Standard: 0.6 – 0.7 mm (0.024 – 0.028 in) ....For E-02, 19, 24, 33...
Page 551 VL800/C/TK9 (’09-MODEL) 18-11 VALVE CLEARANCE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. Valve clearance must be checked and adjusted when: (1) the valve mechanism is service, and (2) the camshafts are serviced.
Page 552 18-12 VL800/C/TK9 (’09-MODEL) • Remove the PAIR pipe bolts (Rear cylinder). • Remove the gasket 5.  Do not reuse the removed gasket. • Remove the inspection caps. • Remove the generator cover plug 6. • Remove the cap 7 and timing inspec ion plug 8.
Page 553 VL800/C/TK9 (’09-MODEL) 18-13 • To inspect the No.1 (Rear) cylinder valve clearance, insert the thickness gauge to the clearance between the valve stem end and the adjusting screw on the rocker arms.  09900-20806: Thickness gauge • If the clearance is out of the specification, bring it into the specified range by using the special tool.
Page 554 18-14 VL800/C/TK9 (’09-MODEL) ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 2 months) and every 18 000 km (11 000 miles, 36 months) thereafter.
Page 555 3.4 L (3.6/3.0 US/Imp qt) Overhaul engine: 3 7 L (3.9/3.3 US/Imp qt)  ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), fil- tering performance and durability which may lead to engine damage or oil leaks.
Page 556 18-16 VL800/C/TK9 (’09-MODEL) THROTTLE CABLE PLAY Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Adjust the throttle cable play A as follows. • Loosen the lock-nut 2 of the throttle pulling cable 1.
Page 557 VL800/C/TK9 (’09-MODEL) 18-17 COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service.
Page 558: Fi System Diagnosis
18-18 VL800/C/TK9 (’09-MODEL) FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM...
Page 559 VL800/C/TK9 (’09-MODEL) 18-19 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) — IAT sensor signal (IAT) ECT sensor signal (ECT) IAP sensor signal #2 (IAP. F) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Power source for sensors (VCC) IAP sensor signal #1 (IAP.
Page 560 18-20 VL800/C/TK9 (’09-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY...
Page 561: Dtc Table And Defective Condition
VL800/C/TK9 (’09-MODEL) 18-21 DTC TABLE 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 signal.
Page 562 18-22 VL800/C/TK9 (’09-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <...
Page 563 VL800/C/TK9 (’09-MODEL) 18-23 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM ISC valve The circuit voltage of motor drive is ISC valve circuit open or shorted C40/P0505 unusual. to the ground Power source circuit open Idle speed is lower than the desired Air passage clogged idle speed.
Page 564: Dtc Troubleshooting
18-24 VL800/C/TK9 (’09-MODEL) DTC TROUBLESHOOTING “C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.
Page 565 VL800/C/TK9 (’09-MODEL) 18-25 “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.
Page 566 18-26 VL800/C/TK9 (’09-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.
Page 567 VL800/C/TK9 (’09-MODEL) 18-27 6) If OK, then check the continuity between each terminal and ground.  STP sensor continuity: ∞ Ω (Infinity)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
Page 568 18-28 VL800/C/TK9 (’09-MODEL) “C40” (P0505/P0506/P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground unusual. (P0505) Idle speed is lower than the desired idle • Air passage clogged (P0506) speed.
Page 569 VL800/C/TK9 (’09-MODEL) 18-29 4) Disconnect the ISC valve coupler and ECM coupler. 5) Check the continuity between terminals A and g, terminals B and ^, terminals C and i, terminals D and \.  When using the multi-circuit tester, do not strongly...
Page 570 18-30 VL800/C/TK9 (’09-MODEL) ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.)  09904-41010: SDS set tool 99565-01010-017: CD-ROM Ver.17 2) Check that the engine is running.
Page 571 VL800/C/TK9 (’09-MODEL) 18-31 Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 400 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC...
Page 572 18-32 VL800/C/TK9 (’09-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION On model K9, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration.
Page 573 VL800/C/TK9 (’09-MODEL) 18-33 “C44” (P0156/P0161) or “C64” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (FOR E-02, 19, 24, 33) DETECTED CONDITION POSSIBLE CAUSE C44/C64 HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0156/ to ECM during engine operation and •...
Page 574 18-34 VL800/C/TK9 (’09-MODEL) 7) Disconnect the ECM coupler. HO2 sensor #1 coupler 8) Check the continuity between W/Bl wire (#1) C and terminal W. (For HO2 sensor #1) Check the continuity between W/G wire (#2) A and terminal 6. (For HO2 sensor #2) 9) Also, check the continuity between B/Br wire B and terminal B.
Page 575 VL800/C/TK9 (’09-MODEL) 18-35 Is the voltage OK? ECM coupler (Harness side) • W/Bl wire or B/Br wire open or shorted to ground, or poor W or B connection. (Rear cylinder side) • W/G wire or B/Br wire open or shorted to ground, or poor 6 or B connection.
Page 576 18-36 VL800/C/TK9 (’09-MODEL) Step 2 (Heater circuit check) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W (O/W) wire and ground.
Page 577 VL800/C/TK9 (’09-MODEL) 18-37 “C62” (P0443) EVAP SYSTEM PURGE CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION (E-33 only) DETECTED CONDITION POSSIBLE CAUSE EVAP system purge control solenoid valve voltage is • EVAP system purge control solenoid valve circuit not input to ECM. open or short.
Page 578 18-38 VL800/C/TK9 (’09-MODEL) Step 2 1) Connect the purge control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Measure the voltage at the wire side coupler between O/W wire and ground.  PAIR control solenoid valve voltage: Battery voltage (+ O/W –...
Page 579 VL800/C/TK9 (’09-MODEL) 18-39 THROTTLE BODY CONSTRUCTION E-33 only 1 STP sensor 0 Air screw 2 O-ring A Straight plug  3 TP sensor B IAP sensor 4 ISC valve C 3-way joint (E-33 only) ITEM N·m kgf-m lbf-ft 5 Delivery pipe A STP sensor mounting bolt 0.35...
Page 580 18-40 VL800/C/TK9 (’09-MODEL) THROTTLE BODY REMOVAL • Remove the air cleaner box. (Page 18-8) • Remove the IAP sensors (Front cylinder side 1 and Rear cyl- inder side 2) from the mounting stay. • Remove the PCV hose 3 and loosen the clamp screw 4.
Page 581 VL800/C/TK9 (’09-MODEL) 18-41 • Loosen the throttle body clamp screw at the intake pipe side. • Move the throttle body upward. • Disconnect the vacuum hoses A. • Disconnect the hoses B. (For E-33) • Disconnect the throttle cables from their drum.
Page 582 18-42 VL800/C/TK9 (’09-MODEL) THROTTLE BODY DISASSEMBLY • Remove the fuel feed hose 1. • Remove the clamp 2. • Loosen the screw and remove the plate 3. • Pull on the straight plug 4 straightly outward to remove it so as not to cause scratches on the O-ring seat of the delivery pipe.
Page 583 VL800/C/TK9 (’09-MODEL) 18-43 • When removing the fuel injector 7, pull it straightly so as not to cause scratches on the O-ring seat of delivery pipe.  Never remove the L-joint 8. • Remove the TP sensor 9 and STP sensor 0 with the special tool.
Page 584 18-44 VL800/C/TK9 (’09-MODEL)  Never remove the STVA B from the throttle body.  Never remove the secondary throttle valve C and throttle valve D.  The adjusting screw E is factory-adjusted at the time of delivery and do not turn or remove it.
Page 585 VL800/C/TK9 (’09-MODEL) 18-45 THROTTLE BODY CLEANING  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 586: Throttle Body Reassembly
18-46 VL800/C/TK9 (’09-MODEL) THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • Apply thin coat of engine oil to the O-ring.  Replace the O-ring with a new one.
Page 587 VL800/C/TK9 (’09-MODEL) 18-47 • With the STV fully opened, install the STP sensor 2 and tighten the STP sensor mounting screw to the specified torque.  TPS and STPS resemble each other very closely in external appearance. Make sure to check the color of coupler before install- ing.
Page 588 18-48 VL800/C/TK9 (’09-MODEL) • Apply thin coat of engine oil to the new O-rings and cushion seals.  Replace the O-rings and cushion seals with the new ones. • Install the fuel injector 4 by pushing it straight to the delivery pipe 5.
Page 589 VL800/C/TK9 (’09-MODEL) 18-49 • Before installing the straight joint 7, clean its inside and out- side. • Apply thin coat of the engine oil to the O-rings.  Replace the O-rings with the new ones. • Insert both the straight joint 7 and straight plug 8 straightly into the delivery pipe.
Page 590: Throttle Body Installation
18-50 VL800/C/TK9 (’09-MODEL) THROTTLE BODY INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Connect the sensor lead wire couplers.  * TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.
Page 591: Stp Sensor Adjustment
VL800/C/TK9 (’09-MODEL) 18-51 STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the fuel tank. ( Page 14-93) • Disconnect the STVA coupler 1.
Page 592: Tp Sensor Adjustment
18-52 VL800/C/TK9 (’09-MODEL) TP SENSOR ADJUSTMENT After all adjustments are completed, check or adjust the TPS setting condition. 1. Remove the right frame cover. ( Page 7-2) 2. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. ( Page 14-37) 3.
Page 593: Isc Valve Removal
VL800/C/TK9 (’09-MODEL) 18-53 ISC VALVE REMOVAL • Remove the throttle body. (Page 18-40) • Remove the ISC valve 1. ISC VALVE INSTALLATION Install the ISC valve in the reverse order of removal. Pay attention to the following points:  * The ISC valve must be installed with the valve fully contracted (full open position).
Page 594: Isc Valve Preset And Opening Initialization
18-54 VL800/C/TK9 (’09-MODEL) ISC VALVE PRESET AND OPENING INITIALIZATION When removing or replacing the ISC valve, set the ISC valve in the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.)
Page 595: Throttle Valve Synchronization
VL800/C/TK9 (’09-MODEL) 18-55 THROTTLE VALVE SYNCHRONIZATION USE OF SDS TOOL Check and adjust the throttle valve synchronization between two cylinders. Step 1 • Lift and support the fuel tank. ( Page 14-93) • Disconnect the vacuum hoses 1 from the throttle body.
Page 596 18-56 VL800/C/TK9 (’09-MODEL) • Click “Active control”. • Click “ISC air volume control” 1. • Click “ON” bottom 2 to fix the ISC air volume of two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 90 – 110 °C (194 – 230 °F).
Page 597: Ignition System
VL800/C/TK9 (’09-MODEL) 18-57 IGNITION SYSTEM Engine stop switch sensor 1 sensor 2 Ignition coil Side- stand #1(main) relay Spark plug sensor Fuse #1(sub) Ignition (E-02, 19, 24, 33 only) switch #2(main) Fuse #2(sub) Battery (E-02, 19, 24, 33 only) sensor...
Page 598 18-58 VL800/C/TK9 (’09-MODEL) Measure the ignition coils primary peak voltage in the following Peak volt adaptor procedures: • Connect the multi-circuit tester with peak voltage adaptor as Ignition follows. coil #1 ignition coil (main): + Probe: B/Bl terminal spark - Probe: Ground...
Page 599 VL800/C/TK9 (’09-MODEL) 18-59 IGNITION COIL PRIMARY PEAK VOLTAGE (For E-03, 28) For details other than the following, refer to the VL800 service manual 8-18. • Connect the multi-circuit tester with peak voltage adaptor as follows. #1 ignition coil: + Probe: B/Bl terminal...
Page 600: Combination Meter Inspection
18-60 VL800/C/TK9 (’09-MODEL) COMBINATION METER INSPECTION LED (LIGHT EMITTING DIODE) Check that the LED lights (FI indicator light, Oil pressure indicator light and Engine coolant indicator light) immediately after turning the ignition switch ON. Also, other LED lights (Neutral indicator light, High-beam indicator light and Turn signal indicator light) can be checked by depending on each switch position.
Page 601: Wiring Harness Routing
VL800/C/TK9 (’09-MODEL) 18-61 WIRING HARNESS ROUTING Clamp Wiring harness Guide Speed sensor Clamp 5 – 25 mm (0.20 – 0.98 in) Handlebar switch (L) Clutch cable White tape 200 mm Handlebar switch (R) Clamp Brake hose Wiring harness Handlebar switch 45˚...
Page 602: Mm (5.55 In)
18-62 VL800/C/TK9 (’09-MODEL) Turn down. Speedometer harness Clutch cable 0 – 5 mm Clamp (0.0 – 0.2 in) – 0 High tension cord 0 – 20 mm Wiring harness (0.0 – 0.8 in) High tension cord Clamp Frame Fuel tank 50 –...

Suzuki VL800 Service Manual

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505 Vl800/Tk6 ('06-Model)

506 Specifications

507 Service Data

516 Special Tools

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Summary of Contents for Suzuki VL800

323
Chassis

337
Vl800K4 ('04-Model)

353
Vl800K5 ('05-Model)

505
Vl800/Tk6 ('06-Model)

506
Specifications

507
Service Data

516
Special Tools

517
Conrod/Crankshaft

522
Emission Control Systems

523
Vl800/Tk7 ('07-Model)

542
Vl800/C/ Tk9 ('09-Model)

323
Chassis

337
Vl800K4 ('04-Model)

353
Vl800K5 ('05-Model)

505
Vl800/Tk6 ('06-Model)

506
Specifications

507
Service Data

516
Special Tools

517
Conrod/Crankshaft

522
Emission Control Systems

523
Vl800/Tk7 ('07-Model)

542
Vl800/C/ Tk9 ('09-Model)