FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI VZR1800 and procedures for its inspection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.
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.
Use engine oil unless otherwise speci- 99000-99032-11X fied. Apply molybdenum oil solution. Use fork oil or equivalent. (Mixture of engine oil and SUZUKI 99000-99044-L01 MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A” or equivalent. Apply or use brake fluid.
ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Fuel Injection, Fuel Injector : Alternating Current : Fuel Pump : Air Cleaner, Air Cleaner Box : Fuel Pressure Regulator : American Petroleum Institute FP Relay : Fuel Pump Relay ATDC : After Top Dead Center : Air Fuel Mixture...
: 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...
WIRE COLOR : Black : Green : Pink : Blue : Gray : Red : Brown : Light blue : White : Dark green : Light green : Yellow : Dark gray : Orange B/Bl : Black with Blue tracer B/Br : Black with Brown tracer : Black with Green tracer...
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.
GENERAL INFORMATION " * 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 and orientation.
GENERAL INFORMATION SUZUKI VZR1800K6 (’06-MODEL) RIGHT SIDE LEFT SIDE • Difference between illustration and actual motorcycle may exist depending on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe.
Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.
GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses.
GENERAL INFORMATION INFORMATION LABELS VZR1800 VZR1800UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Fuel information label 6 Manual notice label A (For E-03, 33) 7 Tire information label...
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 450 mm (96.5 in) ..For E-03, 33 2 480 mm (97.6 in) ..For others Overall width ............875 mm (34.4 in) Overall height ............1 185 mm (46.7 in) Wheelbase ............
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. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be required on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE 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. Brake lever holder Throttle cable Brake pedal pivot Clutch lever holder Side-stand pivot and Gearshift link pivot spring hook NOTE:...
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 6 000 km (4 000 miles, 12 months) and replace every 18 000 km (11 000 miles, 36 months). •...
PERIODIC MAINTENANCE • Carefully use air hose to blow the dust from the cleaner ele- ment. " Always use air pressure on the center air cleaner side of the air cleaner element. If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.
PERIODIC MAINTENANCE EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Tighten the exhaust pipe bolts, muffler mounting bolt and nut to the specified torque.
PERIODIC MAINTENANCE EXHAUST CONTROL VALVE Inspect initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. • Remove the rubber cover 1. Check the exhaust control valve actuator 2 for its movement when the ignition switch is turned on.
PERIODIC MAINTENANCE VALVE CLEARANCE Inspect every 24 000 km (14 500 miles, 48 months). • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Remove the frame head covers and radiator covers. ($9-6) • Remove the air cleaner chamber. ($6-13) •...
PERIODIC MAINTENANCE • Remove the secondary gear case cover. ($3-6) • Remove the generator cover cap 4, valve timing inspection plug 5 and generator cover plug 6. • Turn the crankshaft to set the #1 (Rear) cylinder at TDC of compression stroke.
2-10 PERIODIC MAINTENANCE VALVE CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim. • Remove the intake or exhaust camshafts. ($3-14 to -15 and 3-17 to -18) • Remove the tappet and shim by fingers or magnetic hand. •...
PERIODIC MAINTENANCE 2-13 SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months). replace every 12 000 km (7 500 miles, 24 months). #2 (FRONT) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) •...
2-14 PERIODIC MAINTENANCE #1 (REAR) SPARK PLUG REMOVAL • Remove the frame side covers. ($9-5) • Remove the fuel tank. ($6-3) • Disconnect lead wire coupler 1 from ignition coil/plug cap. " Disconnect the lead wire coupler before removing the ignition coil/plug cap to avoid lead wire coupler dam- age.
PERIODIC MAINTENANCE 2-15 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. If it is white or glazed appearing, replace the spark plug with colder type one.
2-16 PERIODIC MAINTENANCE SPARK PLUG INSTALLATION • Screw the spark plugs into the cylinder head with fingers, and then tighten them to the specified torque. # Spark plug: 11 N·m (1.1 kgf-m, 8.0 Ib-ft) " Do not cross thread or over tighten the spark plug, or such an operation will damage the aluminum threads of the cylinder head.
PERIODIC MAINTENANCE 2-17 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.
Oil and filter change : 3.6 L (3.8/3.2 US/Imp qt) Engine overhaul : 4.7 L (5.0/4.1 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.
PERIODIC MAINTENANCE 2-19 FINAL GEAR OIL Replace initially at 1 000 km (600 miles, 2 months) and inspect every 12 000 km (7 500 miles, 24 months) thereafter. • Keep the motorcycle upright. • Place an oil pan under the final gear case. •...
2-20 PERIODIC MAINTENANCE THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km (600 miles, 2 months) (E-33 only) and every 12 000 km (7 500 miles, 24 moths). Inspect the throttle valve synchronization periodically. ($6-23) COOLING SYSTEM Inspect every 6 000 km (4 000 miles, 12 months). Replace engine coolant every 2 years.
PERIODIC MAINTENANCE 2-21 • Drain engine coolant by disconnecting the radiator hose 2 from the radiator. * Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. * Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes.
2-22 PERIODIC MAINTENANCE RADIATOR HOSES • Remove the fuel tank. ($6-3) • Remove the frame head covers, radiator covers and radiator bottom cover. ($9-6) • Check to see the radiator hoses for crack, damage or engine coolant leakage. • If any defects are found, replace the radiator hoses with new ones.
PERIODIC MAINTENANCE 2-23 BRAKE (BRAKE) Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 12 months). Replace hoses every 4 years.
2-24 PERIODIC MAINTENANCE BRAKE PADS Front brake The extent of brake pad wear can be checked by observing the grooved limit line A on the pad. When the wear exceeds the grooved limit line, replace the pads with the new ones. ($9-52) "...
PERIODIC MAINTENANCE 2-25 BRAKE PEDAL HEIGHT • Loosen the lock nut 1. • Turn the push rod 2 until the brake pedal height becomes 25 – 35 mm (1.0 – 1.4 in) A below the top of the footrest. • Tighten the lock nut 1 securely. # Rear brake master cylinder rod lock nut: 18 N·m (1.8 kgf-m, 13.0 Ib-ft) % Brake pedal height A:...
2-26 PERIODIC MAINTENANCE AIR BLEEDING FROM 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 cyl- inder and thus interferes with the full braking performance of the brake caliper.
PERIODIC MAINTENANCE 2-27 REAR BRAKE • Bleed air from the rear brake system in the same manner as front brake. # Air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 Ib-ft) NOTE: The only of between operation from bleeding the front brake is that the rear master cylinder is actuated by a pedal.
2-28 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. % Cold inflation tire pressure Solo riding: Front: 250 kPa (2.50 kgf/cm , 36 psi)
PERIODIC MAINTENANCE 2-29 REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 24 months). • Remove the under cover. ($9-41) Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm. Replace any defective parts if necessary.
PERIODIC MAINTENANCE 2-31 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...
2-32 PERIODIC MAINTENANCE 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 400 – 700 kPa (4.0 – 7.0 kgf/cm , 57 – 100 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.
PERIODIC MAINTENANCE 2-33 SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.
2-34 PERIODIC MAINTENANCE Data at 3 000 r/min under no load Approx. 3 000 r/min Check the water temperature. XX ˚C ˚ Check the manifold absolute pressure #1. XX mmHg Data at the time of racing ˚ Check the manifold absolute pressure #1 in according with the throttle valve opening.
PERIODIC MAINTENANCE 2-35 Data of intake negative pressure during idling (100 °C) ˚ Check the water temperature. Approx. 100 ˚C Check the manifold absolute pressure #1. XX mmHg Data of manifold absolute pressure operation at the time of starting Check the manifold absolute pressure #1. XX mmHg Check the manifold absolute pressure #2.
ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ..3- 2 ENGINE REMOVAL AND INSTALLATION..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ..............3- 9 ENGINE DISASSEMBLY ................3-13 ENGINE COMPONENTS INSPECTION AND SERVICE......3-29 CYLINDER HEAD COVER..............3-29 CAMSHAFT ...................
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 page listed in each section for removal and reinstallation instructions. ENGINE CENTER ITEM REMOVAL INSPECTION INSTALLATION !12-6...
ENGINE 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 procedure. • Drain engine oil. (!2-17) •...
ENGINE • Disconnect the ECT sensor lead wire coupler 4. • Disconnect the ignition coil/plug cap lead wire couplers and remove the ignition coils/plug caps. (!2-13 and -14) " * Do not remove the ignition coil/plug cap before dis- connecting its coupler. * Do not pry up the ignition coil/plug cap with a screw driver or a bar to avoid its damage.
ENGINE • Remove the right footrest 8. • Disconnect the starter motor lead wire 9. • Disconnect the oil cooler hose 0. • Remove the oil pressure switch lead wire A.
ENGINE • Disconnect the cooling fan coupler B and horn lead wire cou- plers C. • Remove the left frame lower side cover D. • Remove the secondary gear case cover E. • Disconnect the generator lead wire coupler F. •...
ENGINE • Remove the clutch cable K. • Support the engine with an engine jack. • Remove the left footrest L and gearshift lever M. • Remove the ground lead wire N. • Disconnect the GP switch lead wire coupler O. •...
ENGINE • Slightly move the frame down tube by removing its bolts P, bolts and nuts Q. • Remove the caps. • Remove the engine mounting bracket bolts R. • Remove the engine mounting bolts and nuts S. • Remove the the engine assembly.
ENGINE ENGINE INSTALLATION Install the engine in the reverse order of engine removal. Pay attention to the following points: • Install the boot and universal joint. NOTE: Make sure that the “UP” mark A faces up. • Gradually raise the engine, and then engage the secondary driven gear shaft to the universal joint.
3-10 ENGINE • Install the frame down tube and tighten the bolts 2, bolts and nuts 3 to the specified torque. NOTE: The frame down tube nuts are self-locking. Once the nuts have been removed, they are no longer of any use. # Frame down tube bolt: 50 N·m (5.0 kgf-m, 36.0 lb-ft) •...
ENGINE 3-11 NOTE: The engine mounting nuts are self-locking. Once the nut has been removed, they are no longer of any use. Right Left 3 Bushing Engine mounting nut 4 Bushing Spacer ITEM N·m kgf-m lb-ft 40.0 • Install the gearshift lever and tighten the mounting bolts to the specified torque.
3-12 ENGINE • Tighten the right front footrest mounting bolts to the specified torque. # Right front footrest bolt: 60 N·m (6.0 kgf-m, 43.5 lb-ft) • Install the rear brake master cylinder cover 4. (!9-72) • Install the throttle body. (!6-21) •...
ENGINE 3-13 ENGINE DISASSEMBLY " Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their origi- nal positions. • Remove the front and rear spark plugs. STARTER MOTOR •...
3-14 ENGINE REAR CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the rear cylinder head cover 2 and its gasket. REAR CAMSHAFT • Remove the generator cover cap 1. • Remove the valve timing inspection plug 2 and generator cover plug 3.
ENGINE 3-15 • Turn the crankshaft to bring the “R I T” line on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown. NOTE: At the above condition, the rear cylinder is at TDC of compres- sion stroke and also the engraved lines A on the camshafts are parallel with the mating surface of the cylinder head cover.
3-16 ENGINE REAR CYLINDER HEAD • Remove the cylinder head bolts and washers. NOTE: Loosen the cylinder head bolts little by little diagonally with the smaller sizes first. • Remove the cylinder head 1. REAR CYLINDER • Remove the cylinder head gasket 1, dowel pins 2 and cam chain guide No.
ENGINE 3-17 FRONT CYLINDER HEAD COVER • Remove the right and left head cover brackets 1. • Remove the front cylinder head cover 2 and its gasket. FRONT CAMSHAFT • Turn the crankshaft to bring the “F I T” line mark on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown.
3-18 ENGINE • Remove the cam chain guide No. 3 5. • Remove the camshaft journal holder 6. • Remove the dowel pins. " Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.
ENGINE 3-19 • Remove the cylinder nuts. • Remove the cylinder 5. NOTE: Firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose.
3-20 ENGINE • Remove the clutch push rod 5 and clutch push rod release ball 6. NOTE: If it is difficult to pull out the push rod 5 and ball 6, use a long- bar. • Unlock the clutch sleeve hub nut. •...
ENGINE 3-21 • Remove the thrust washer A. • Remove the primary driven gear assembly B. • Remove the needle roller bearing C and spacer D. REAR CAM CHAIN TENSION ADJUSTER • Unlock the ratchet 1 and insert the special tool. % 09917-62430: Chain tensioner lock tool •...
3-22 ENGINE • Remove the cam chain No. 2 4, rear cam chain idler sprocket 5 and cam chain No. 1. REAR CAM CHAIN DRIVE SPROCKET • Hold the generator rotor and remove the rear cam chain drive sprocket bolt. "...
ENGINE 3-23 NOTE: When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. • Remove the generator rotor assembly with the special tool. % 09930-30721: Rotor remover •...
3-24 ENGINE • Remove the cam chain tensioner No. 1 6. • Remove the cam chain No. 2 7, front cam chain idler sprocket 8 and cam chain No. 1 9. • Remove the front cam chain tension adjuster No. 1 0. SECONDARY DRIVEN GEAR •...
ENGINE 3-25 • Remove the gearshift cam plate 3. • Remove the gearshift cam stopper 4. SECONDARY DRIVE GEAR • Shift the gear position to 1st or 2nd. • Hold the primary driven gear with the special tool. % 09930-44541: Rotor holder •...
3-26 ENGINE • Remove the oil pump drive gear 5 and pin 6. GEAR POSITION SWITCH • Remove the gear position switch 1. OIL FILTER • Remove the oil filter with the special tool. % 09915-40610: Oil filter wrench OIL COOLER/OIL PRESSURE SWITCH •...
ENGINE 3-27 OIL PAN • Remove the oil pan 1 and stay 2. OIL PRESSURE REGULATOR • Remove the oil pressure regulator 1. OIL STRAINER • Remove the oil strainers 2 and O-rings 3. UPPER CRANKCASE • Remove the breather cover 1. •...
3-28 ENGINE NOTE: * The crankshaft and transmission components should remain in the upper crankcase half. * If it is difficult to separate the crankcase halves, set the proper bolts and nuts to the crankcase by separating the upper and lower crankcase halves, as shown in the illustration.
ENGINE 3-29 ENGINE COMPONENTS INSPECTION AND SERVICE " Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, No.1 or No.2) so that they can be installed in their original locations. CYLINDER HEAD COVER DISASSEMBLY •...
3-30 ENGINE CAM WEAR • Check the camshaft for wear or damage. • Measure the cam height H with a micrometer. $ Cam height H: Service Limit: (IN. & EX.): 40.580 mm (1.5976 in) % 09900-20202: Micrometer (25 – 50 mm) CAMSHAFT JOURNAL WEAR •...
ENGINE 3-31 • If the camshaft journal oil clearance measured exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal. • Replace the camshaft or the cylinder head depending upon which one exceeds the specification. $ Camshaft journal holder I.D.: Standard: (IN.