Suzuki 2010 VZ800L0 Supplementary Service Manual
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Suzuki 2010 VZ800L0 Supplementary Service Manual

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Summary of Contents for Suzuki 2010 VZ800L0

  • Page 2: Table Of Contents

    REMOVAL AND DISASSEMBLY ............. 18 LAMPS........................ 21 HEADLIGHT, BRAKE/TAIL LIGHT, LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT......21 WIRING HARNESS ROUTING................23 CABLE ROUTING ....................25 FRONT BRAKE ROUTING ................26 SPEED SENSOR HARNESS ROUTING............27 © COPYRIGHT SUZUKI MOTOR CORPORATION 2009...
  • Page 3 2 VZ800L0 (’10-MODEL) VZ800L0 (’10-MODEL) CONTENTS HEAD LIGHT INSTALLATION ................28 REAR COMBINATION LAMP INSTALLATION ..........29 FRAME HEAD COVER CUSHION INSTALLATION ......... 30 LEFT SIDE COVER CUSHION INSTALLATION ..........30 TAIL LAMP INSTALLATION ................31 IGNITION COIL INSTALLATION............... 32 SEATLOCK CABLE ROUTING.................

  • Page 4: Information Labels

    VZ800L0 (’10-MODEL) 3 INFORMATION LABELS VZ800L0 1 Tire information label A: Attached Except for E-03, 33 For E-03, 33...

  • Page 5: Specifications

    4 VZ800L0 (’10-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................* 2 420 mm (95.3 in)....E-02, 19, 24 * 2 395 mm (94.3 in)....E-03, 28, 33 Overall width ..................* 890 mm (35.0 in) Overall height ..................* 1 105 mm (43.5 in) Wheelbase ..................

  • Page 6: Sensor

    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)

  • Page 7: Exterior Parts

    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 •...

  • Page 8: Remounting

    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. ...

  • Page 9: Front Fork

    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.
  • Page 10 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 •...
  • Page 11 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.

  • Page 12: Inspection

    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 •...

  • Page 13: Reassembly And Remounting

    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.
  • Page 14 • 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.
  • Page 15 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.
  • Page 16 • 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.

  • Page 17: Ignition System

    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.

  • Page 18: Speedometer And Pilot Lamp Box

    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.

  • Page 19: Speedometer/Headlight Cover Brace Removal And Disassembly

    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.
  • Page 20 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.
  • Page 21 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...

  • Page 22: Lamps

    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 ......
  • Page 23 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.

  • Page 24: Wiring Harness Routing

    VZ800L0 (’10-MODEL) 23 WIRING HARNESS ROUTING Clamp Handlebar switch (L & R) Wiring harness Clamp Speed sensor Handlebar switch (R) Clamp Clamp Handlebar switch (L) VIEW A Handlebar switch (L & R) 150 ± 10 mm Wirring harness 100 ± 10 mm (4.0 ± 0.4 in) (5.9 ±...
  • Page 25 24 VZ800L0 (’10-MODEL) Turn down. Indicator lamp harness Clutch cable Clamp Reservoir High tension cord 0 – 20 mm hose (0 – 0.8 in) IG coil lead wire Frame High tension cord Wiring harness Air cleaner Clamp Frame Fuel tank 50 –...

  • Page 26: Cable Routing

    VZ800L0 (’10-MODEL) 25 CABLE ROUTING Throttle cable clip 170 mm (6.7 in) Throttle cable Outside Clutch cable Fuel tank cushion PAIR control solenoid valve lead wire Outside Clutch cable High tension code Fuel tank cushion bar (RH) Clutch cable Clutch cable Throttle cable Clutch cable No.1...

  • Page 27: Front Brake Routing

    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.

  • Page 28: Speed Sensor Harness Routing

    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.

  • Page 29: Head Light Installation

    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...

  • Page 30: Rear Combination Lamp Installation

    VZ800L0 (’10-MODEL) 29 REAR COMBINATION LAMP INSTALLATION 5 N . m (0.5 kgf-m, 3.6 lbf-ft) (E-03, 28, 33) 1.8 N . m 0.18 kgf-m 1.3 lbf-ft (E-02, 19, 24) 1 Rear combination lamp 5 Right turn signal lamp 2 License lamp 6 Left turn signal lamp 3 License plate bracket 7 Rear fender extension...

  • Page 31: Frame Head Cover Cushion Installation

    30 VZ800L0 (’10-MODEL) FRAME HEAD COVER CUSHION INSTALLATION 1 Cushion 4 5 mm (0.20 in) 7 10 mm (0.39 in) 2 3 mm (0.12 in) 5 15 mm (0.59 in) 3 12 mm (0.47 in) 6 20 mm (0.79 in) LEFT SIDE COVER CUSHION INSTALLATION 1 Cushion 2 25 mm (1.06 in)

  • Page 32: Tail Lamp Installation

    VZ800L0 (’10-MODEL) 31 TAIL LAMP INSTALLATION Clamp (Pipe) Rear fender Pipe License lamp Rear turn signal (L&R) Clamp 20 – 30 mm (0.8 – 1.2 in) 10 – 20 mm Pipe (0.4 – 0.8 in) Rear combination Rear combination lamp harness lamp Clamp Rear turn signal (L&R)

  • Page 33: Ignition Coil Installation

    32 VZ800L0 (’10-MODEL) IGNITION COIL INSTALLATION 0 ± 10˚ 0 ± 10˚ “FS” mark “RS” mark “FS” mark “RS” mark  1 Ignition coil #1 (main) 2 Ignition coil #1 (sub) ITEM N·m kgf-m lbf-ft 3 Ignition coil #2 (main) 0.45 4 Ignition coil #2 (sub) 5 Protector...

  • Page 34: Seatlock Cable Routing

    VZ800L0 (’10-MODEL) 33 SEATLOCK CABLE ROUTING Clamp Rear fender Rear fender Seat lock cable Clamp Rear ignition coil VIEW B Luggage box Frame Rear frame Seat lock cable Frame Luggage box Rear frame VIEW C Clamp Luggage box Seat lock cable VIEW A Rear fender Set the seat lock cable firmly.

  • Page 35: Rear Fender Installation

    34 VZ800L0 (’10-MODEL) REAR FENDER INSTALLATION...

  • Page 36: Rear Frame Installation

    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.

  • Page 37: Tightening Torque

    36 VZ800L0 (’10-MODEL) TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lbf-ft Clutch cable adjuster lock-nut (engine side) 0.45 CHASSIS ITEM N·m kgf-m lbf-ft Front fork damper rod bolt 16.5 Rear frame mounting bolt 36.0 Rear fender brace bolt 16.5 License lamp mounting nut Rear reflex reflector mounting nut 0.18...

  • Page 38: Service Data

    * 374 (15.04) (14.7) Front fork oil level (without spring) ---- (6.02) Front fork oil type SUZUKI FORK OIL L01 ---- or an equivalent fork oil Front fork oil capacity (each leg) * 541 ml ---- (18.3/19.0 US/Imp oz) Front fork inner tube outside diam.

  • Page 39: Wiring Diagram

    WIRING DIAGRAM For E-02, 19, 24 Wiring diagrams wire color, refer to VZ800 service manual section “WIRE COLOR”. HANDLEBAR SWITCH (R) F : FI INDICATOR LIGHT ENGINE H : HI-BEAM INDICATOR LIGHT STOP STARTER FRONT BRAKE N : NEUTRAL INDICATOR LIGHT SWITCH BUTTON SWITCH...

  • Page 40: For E-02, 19, 24

    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)
  • Page 41 Prepared by August, 2009 Part No. 99501-38110-01E Printed in Japan...

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