VZ800L0 (’10-MODEL) 5 SENSOR HO2 SENSOR INSPECTION The heated oxygen sensors are installed on the front exhaust pipe and rear muffler. (VZ800K9 32 to 35) NOTE: Difference between L0-MODEL and K9-MODEL is addition of HO2 sensor to E-03, 28. HO2 SENSOR REMOVAL/INSTALLATION (VZ800K5 5-78 and VZ800K9 69)
6 VZ800L0 (’10-MODEL) EXTERIOR PARTS REMOVAL SEAT • Remove the left frame cover. (Below) • Pull the seat lock cable 1 and remove the front seat 2. • Remove the rear seat 3 by removing the bolts. FRAME COVER • Remove the left frame cover 1 with the ignition key. : Hooked part •...
VZ800L0 (’10-MODEL) 7 REAR FENDER • Remove the front and rear seat. (Page 6) • Disconnect the coupler 1. • Remove the seat lock cable 2. • Remove the left and right side rear frame. • Remove the rear fender 3. ...
8 VZ800L0 (’10-MODEL) FRONT FORK REMOVAL AND DISASSEMBLY • Remove the front wheel. (VZ800K5 8-7) • Remove the front brake caliper. (VZ800K5 8-52) • Remove the front fender. • Loosen the front fork upper clamp bolt 1. NOTE: Slightly loosen the front fork cap bolt 2 before loosening the lower clamp bolt to facilitate later disassembly.
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VZ800L0 (’10-MODEL) 9 • Separate the front fork cap bolt from the front fork. • Compress the front fork spring with the special tool A and insert the special tool B between the lock-nut and the spacer. 09940-94930: Front fork spacer holder A 09940-94922: Front fork spring stopper plate B •...
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10 VZ800L0 (’10-MODEL) • Remove the damper rod bolt. NOTE: If the damper rod bolt cannot be removed, insert an appropriate rod A, for example, long flat blade screwdriver, into the gap B between inner tube and damper rod to prevent the damper rod from rotating.
VZ800L0 (’10-MODEL) 11 • Remove the oil seal stopper ring 8. • Remove the oil seal 9 with the special tool. 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. • Remove the oil seal retainer 0. INSPECTION INNER AND OUTER TUBES •...
12 VZ800L0 (’10-MODEL) DAMPER ROD Move the inner rod by hand to examine it for smoothness. If any defects are found, replace inner rod/damper rod (car- tridge) with a new one. REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly.
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• Pour specified front fork oil up to the top level of the outer tube. Capacity (each leg): 541 ml (18.3/19.0 US/lmp oz) 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent fork oil • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
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14 VZ800L0 (’10-MODEL) • Refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until no more bubbles come out from the oil. • Keep the front fork vertically and wait 5 – 6 minutes. NOTE: * Always keep oil level over the cartridge top end, or air may enter the cartridge during this procedure.
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• Remove the special tools. • Apply fork oil to the O-ring and temporarily tighten the fork cap bolt 1 to the outer tube. 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent fork oil Use a new O-ring to prevent oil leakage.
16 VZ800L0 (’10-MODEL) IGNITION SYSTEM IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION (VZ800K9 Page 56) NOTE: Difference between L0-MODEL and K9-MODEL is addition of twin spark plug to E-03, 28.
VZ800L0 (’10-MODEL) 17 SPEEDOMETER AND PILOT LAMP BOX DESCRIPTION This speedometer mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emit- ting Diode). This speedometer is light, thin and of high response compared to those currently in use because of this composition.
18 VZ800L0 (’10-MODEL) SPEEDOMETER/HEADLIGHT COVER BRACE REMOVAL AND DISASSEMBLY • Disconnect the headlight coupler 1. • Remove the headlight. (Page 28) • Disconnect the speedometer lead wire coupler. When disconnecting and reconnecting the speedome- ter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
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VZ800L0 (’10-MODEL) 19 • Disconnect the clamps 2. • Disconnect the speed sensor coupler 3, handlebar switch couplers 4 and front turn signal light couplers 5. • Remove the headlamp brace 6.
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20 VZ800L0 (’10-MODEL) • Disassemble the speedometer as follows. Do not attempt to disassemble the speedometer unit. 1 Upper cover 3 Speedometer 5 Pilot lamp box assembly 2 Upper case assembly 4 Lower case...
VZ800L0 (’10-MODEL) 21 LAMPS HEADLIGHT, BRAKE/TAIL LIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT HEADLIGHT 12 V 60/55 W POSITION LIGHT 12 V 5 W (E-02, 19, 24) BRAKE/TAIL LIGHT LICENCE PLATE LIGHT 12 V 5 W TURN SIGNAL LIGHT Front 12 V 21/5 W ......
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22 VZ800L0 (’10-MODEL) HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam. A: Vertical adjuster B: Horizontal adjuster NOTE: To adjust the headlight beam, adjust the beam horizontally first, then adjust vertically.
26 VZ800L0 (’10-MODEL) FRONT BRAKE ROUTING 42˚ VIEW B VIEW A VIEW C *3 Clamp the sleeve firmly. After the brake hose union touching to the stopper, tighten the union bolt. *4 Set the clamp with stopper before tightening. *2 Pass the brake hose outside of the guide. *5 Pass the brake hose outside of the throttle cable.
VZ800L0 (’10-MODEL) 27 SPEED SENSOR HARNESS ROUTING 15 – 25 mm (0.6 – 1.0 in) 1 Clamp *1 Pass the speed sensor harness in front of the brake hose and guide. 2 Clip *2 Pass the speed sensor harness in front of the brake hose guide. 3 Yellow mark *3 Do not catch the speed sensor harness to the caliper boss.
28 VZ800L0 (’10-MODEL) HEAD LIGHT INSTALLATION VIEW A 1 Head lamp cover 4 Left turn signal lamp 2 Head lamp 5 Right turn signal lamp 3 Head lamp brace 6 Front turn signal lamp cover...
VZ800L0 (’10-MODEL) 35 REAR FRAME INSTALLATION 50 N . m (5.0 kgf-m, 36 lbf-ft) Rear frame Frame 50 N . m (5.0 kgf-m, 36.0 lbf-ft) *1 After temporary tightening, tighten the bolts to the specified torque in order of A→B→C.
For E-03, 28 HANDLEBAR SWITCH (R) F : FI INDICATOR LIGHT ENGINE H : HI-BEAM INDICATOR LIGHT STOP STARTER FRONT BRAKE N : NEUTRAL INDICATOR LIGHT SWITCH BUTTON SWITCH T : TURN SIGNAL INDICATOR LIGHT PUSH PILOT LAMP SPEEDOMETER FUEL PUMP IGNITION IGNITION COIL (R-I)
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Prepared by August, 2009 Part No. 99501-38110-01E Printed in Japan...
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