Suzuki VL800 Manual
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Suzuki VL800 Manual

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  • Page 2 Therefore, please fol- low the maintenance instructions closely to ensure emission com- NOTICE pliance. Your authorized Suzuki dealer has experienced techni- Indicates a potential hazard cians that are trained to provide that could result in vehicle or your machine with the best possi- equipment damage.
  • Page 3 Suzuki reserves the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehi- cles previously built or sold.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS THE SPORT OF MOTORCYCLING FUEL, OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 6: The Sport Of Motorcycling

    THE SPORT OF MOTORCYCLING MOST ACCIDENTS CAN BE AVOIDED ............. 1-2 IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE ..............1-3 IF A COLLISION IS IMMINENT, DO SOMETHING! ........... 1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......... 1-4 KNOW YOUR LIMITS ..................

  • Page 7: Most Accidents Can Be Avoided

    THE SPORT OF MOST ACCIDENTS CAN BE MOTORCYCLING AVOIDED The most common type of motor- cycle accident in the U.S. occurs Your motorcycle and this owner’s when a car traveling toward a manual have been designed by motorcycle turns left in front of the people like you who enjoy motor- motorcycle.

  • Page 8: If You Don't Have A Helmet - Buy A Helmet, And Wear It Every Time You Ride

    IF YOU DON’T HAVE A IF A COLLISION IS IMMINENT, HELMET - BUY A HELMET, AND DO SOMETHING! WEAR IT EVERY TIME YOU RIDE Many riders fear locking up their brakes or haven’t learned to Most accidents occur within a few swerve to avoid an accident.

  • Page 9: Special Situations Require Special Care

    Emergency stopping and swerv- SPECIAL SITUATIONS REQUIRE ing are techniques that you SPECIAL CARE should practice and master before Of course, there are some times you find yourself in an emergency when full-force braking is not the situation. The best place to prac- correct technique.

  • Page 10: Know Your Limits

    KNOW YOUR LIMITS BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS Always ride within the boundaries of your own skills. Knowing these Riding on bad weather days, limits and staying within them will especially wet ones, requires help you avoid accidents. extra caution.

  • Page 11: Practice Away From Traffic

    PRACTICE AWAY FROM TRAFFIC CARRYING A PASSENGER Your riding skill and your mechan- Carrying a passenger, when done ical knowledge form the founda- correctly, is a great way to share tion for safe riding practices. We the joy of motorcycling. You will suggest that you practice riding have to alter your riding style your motorcycle in a nontraffic sit-...

  • Page 12: Motorcycle Safety Foundation's "Riding Tips And Practice Guide" Handbook (For Owners In Usa)

    Make sure you mental or advanced riding skills understand all of the labels. Do course nearest you, or owners in not remove any labels from the the USA can call toll-free 1-800- motorcycle. 446-9227. Good riding on your new Suzuki!

  • Page 14: Fuel, Oil And Coolant Recommendations

    FUEL, OIL AND COOLANT RECOMMENDATIONS FUEL ........................2-2 ENGINE OIL ......................2-4 GEAR OIL ......................2-5 ENGINE COOLANT SOLUTION ................. 2-6...

  • Page 15: Fuel

    If the situation is not more than 10% ethanol. Make improved by changing, consult sure this gasoline-ethanol blend your Suzuki dealer. has octane ratings no lower than • If pinking or knocking is experi- those recommended for gasoline.
  • Page 16 NOTE: • To help minimize air pollution, Suzuki recommends that you use oxygenated fuels. • Be sure that any oxygenated fuel you use has octane rat- ings of at least 87 pump octane ((R+M)/2 method).

  • Page 17: Engine Oil

    ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of Suzuki recommends the use of SAE 10W-40 engine oil. If SAE SUZUKI PERFORMANCE 10W-40 engine oil is not available, MOTOR OIL or equivalent engine select an alternative according to oil.

  • Page 18: Gear Oil

    Energy Conserving GEAR OIL Suzuki does not recommend the Use an SAE90 hypoid gear oil use of “ENERGY CONSERVING” which is rated GL-5 under the API or “RESOURCE CONSERVING” classification system. If you oper- oils. Some engine oils which have...

  • Page 19: Engine Coolant Solution

     WARNING mends the use of ECSTAR brand coolant. ECSTAR has been spe- Engine coolant is harmful or cially formulated for your SUZUKI fatal if swallowed or inhaled. product and contributes to the Solution can be poisonous to desired motorcycle performance animals.
  • Page 20 1750 ml (1.8 US qt) “SUZUKI SUPER LONG LIFE COOLANT” is pre-mixed to the Engine coolant 875 ml (0.9 US qt) proper ratio. Add only “SUZUKI Water 875 ml (0.9 US qt) SUPER LONG LIFE COOLANT” if coolant level drops. It is not nec- NOTE: This 50% mixture will essary to dilute “SUZUKI SUPER...

  • Page 22: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 KEY ........................3-5 IGNITION SWITCH ....................3-5 INSTRUMENT PANEL ..................3-8 LEFT HANDLEBAR ................... 3-14 RIGHT HANDLEBAR ..................3-16 FUEL TANK CAP ....................3-18 GEARSHIFT LEVER ..................3-19 REAR BRAKE PEDAL ..................3-19 HELMET HOLDER ....................

  • Page 23: Location Of Parts

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Front brake lever 8 Fuel tank cap...
  • Page 24 VL800 9 Spark plugs 0 Battery and main fuse A Tools B Helmet holder C Gearshift lever D Footrests E Engine coolant reservoir F Side stand VL800T G Fuses H Passenger footrests...
  • Page 25 VL800 I Air cleaner J Ignition switch K Engine oil filler cap L Engine oil inspection window M Engine oil drain plug N Engine oil filter O Rear brake light switch P Rear brake pedal VL800T...

  • Page 26: Key

    IGNITION SWITCH Two keys come with this motorcy- The ignition switch has 4 posi- cle. Keep the spare key in a safe tions. place. “OFF” position All electrical circuits are cut off. The engine will not start. The key can be removed. “ON”...
  • Page 27 The If the motorcycle falls down, key can be removed and the turn the ignition switch off steering will be locked. immediately. Ask your autho- rized Suzuki dealer to inspect the motorcycle for unseen damage.
  • Page 28 The key hole can be covered by turning the lid. Align the lid hole position with the key hole position when inserting the key.

  • Page 29: Instrument Panel

    SPEEDOMETER 1 INSTRUMENT PANEL The speedometer indicates the road speed in kilometers per hour and miles per hour. If the speedometer needle does not point to zero, follow the proce- dure below to reset the speedom- eter. GEAR 1. Press and hold the button 9 and turn on the ignition switch.
  • Page 30 Check the oil level indicator light goes off. and add oil if necessary. If there is a proper amount of oil and the light still does not go out, have your authorized Suzuki dealer or a qualified mechanic inspect your motor- cycle.
  • Page 31 If the display indicates “FI” and GEAR the fuel injection system indi- cator light comes on, have your authorized Suzuki dealer or a FUEL INJECTION SYSTEM qualified mechanic inspect the INDICATOR LIGHT “FI” 6 fuel injection system as soon as possible.
  • Page 32 To change the display, push the COMBINATION SYSTEM button 8. The display changes in DISPLAY 7 the order below. The display has six functions, clock, odometer, two trip meters, instrument panel light brightness (VL800T) gear position. GEAR When the ignition switch is turned to the “ON”...
  • Page 33 Odometer The odometer registers the total distance that the motorcycle has been ridden. odometer ranges from 0 to 999999. NOTE: The odometer display locks at 999999 when the total distance exceeds 999999. GEAR Trip Meters The two trip meters are resettable odometers.
  • Page 34 Gear Position Indicator HIGH BEAM INDICATOR LIGHT “” A The gear position indicator indi- cates gear position. This indica- This blue indicator light will come displays “0” when on when the headlight high beam transmission is in neutral. is turned on. NOTE: When the display indi- cates “CHEC”, the gear position indicator does not indicate a num-...

  • Page 35: Left Handlebar

    LEFT HANDLEBAR NOTICE Holding the dimmer switch  between the “” and “ ” position will light both the high and low headlight beam. This improper operation can dam- age the motorcycle’s headlight. Use the dimmer switch to  Clutch Lever 1 select only the “”...
  • Page 36 Horn Switch “” 5 Turn Signal light Switch “” Press the switch to sound the Moving the switch to the “” horn. position will flash the left turn sig- Hazard Warning Switch “” 6 nals. Moving the switch to the “” position will flash the right turn All four turn signal lights and indi- signals.

  • Page 37: Right Handlebar

    RIGHT HANDLEBAR Front Brake Lever Adjustment Engine Stop Switch 1 The distance between the throttle “” position grip and the front brake lever is The ignition circuit is off. The adjustable to 5 positions. To engine cannot start or run. change the position, push the brake lever forward and turn the “”...
  • Page 38 NOTE: The headlight will go off and the gear position indica- when the electric starter switch is tor are not working properly, pushed. consult your Suzuki dealer. NOTICE Throttle Grip 4 Engine speed is controlled by the Engaging the starter motor for position of the throttle grip.

  • Page 39: Fuel Tank Cap

    FUEL TANK CAP Fuel level Filler neck  WARNING To open the fuel tank cap, insert the ignition key into the lock and If you overfill the fuel tank, fuel turn it clockwise. With the key may overflow when it expands inserted, lift the cap up with key.

  • Page 40: Gearshift Lever

    GEARSHIFT LEVER REAR BRAKE PEDAL This motorcycle has 5-speed Pressing the rear brake pedal will transmission which operates as apply the rear brake. The brake shown. To shift properly, squeeze light will come on when the rear the clutch lever and close the brake is operated.

  • Page 41: Helmet Holder

    HELMET HOLDER SIDE STAND The motorcycle has a side stand. The helmet holder is located on To place the motorcycle on the the left side below the rear seat. side stand, place your right foot Insert the ignition key into the lock on the end of the side stand and and turn it clockwise to open the push down firmly until the stand...

  • Page 42: Suspension Adjustment

    • Read owner’s manual for If you do not take proper pre- more information. cautions when parking, the motorcycle can fall over. NOTE: Ask your Suzuki dealer to dispose of the rear suspension Park the motorcycle on firm, unit. level ground whenever possi- ble.
  • Page 43 REAR SUSPENSION Spring Pre-load Adjustment The rear suspension spring pre- load is adjustable to compensate for rider, load, riding style and road conditions. The adjustment can be performed in seven posi- tions. To change the spring pre- load setting, follow the procedure below.
  • Page 44 This motorcycles is delivered from factory with adjuster set on position 4. NOTE: Use a hook type spring adjuster or Suzuki spring adjuster, Part number 09822-00003 to adjust the rear suspension spring. The Suzuki spring adjuster is available from your Suzuki dealer. 3-23...

  • Page 46: Break-In And Inspection Before Riding

    BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-3...
  • Page 47 BREAK-IN AND Breaking in the New Tires New tires need proper break-in to INSPECTION BEFORE assure maximum performance, RIDING just as the engine does. Wear in the tread surface by gradually BREAK-IN increasing your cornering lean The first 800 km (500 miles) is the angles over the first 160 km (100 most important in the life of your miles) before attempting maxi-...
  • Page 48 Observe Your Initial and Most INSPECTION BEFORE RIDING Critical Service  WARNING The initial service (1000 km main- tenance) is the most important Failure to inspect your motor- service your motorcycle will cycle before riding and to prop- receive. During break-in opera- erly maintain your motorcycle tion, all of the engine components will have mated together and...
  • Page 49 Check the condition of the motor- Fuel tank Tank cap locked securely cycle to help make sure that you ( 3-18) do not have mechanical problems Lighting Operation of all lights and or get stranded somewhere when ( 3-5, indicators 3-8, 3-14) you ride.

  • Page 50: Riding Tips

    RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF AND SHIFTING ................ 5-4 USING THE TRANSMISSION ................5-5 RIDING ON HILLS ....................5-6 STOPPING AND PARKING ................5-6 CARRYING A PASSENGER ................5-8...

  • Page 51: Starting The Engine

    Turn off the consult your Suzuki dealer. ignition switch before restarting the engine. When the Engine is Cold: 1. Close the throttle completely.
  • Page 52  WARNING NOTICE Exhaust gas contains carbon Running the engine too long monoxide, a dangerous gas without riding may cause the that is difficult to detect engine to overheat. Overheat- because it is colorless and ing can result in damage to odorless.

  • Page 53: Starting Off And Shifting

    STARTING OFF AND SHIFTING  WARNING  WARNING Sudden side winds, which can occur when being passed by Riding at excessive speeds larger vehicles, at tunnel exits increases your chances of los- or in hilly areas, can cause you ing control of the motorcycle, to lose control of the motorcy- which can result in an acci- cle.

  • Page 54: Using The Transmission

    USING THE TRANSMISSION  WARNING The transmission is provided to keep engine operating Downshifting when engine smoothly in its normal operating speed is too high can: speed range. The gear ratios • cause the rear wheel to skid have been carefully chosen to and lose traction due to meet the characteristics of the increased engine braking,...

  • Page 55: Riding On Hills

    RIDING ON HILLS STOPPING AND PARKING • When climbing steep hills, the 1. Twist the throttle grip away motorcycle may begin to slow from yourself to close the down and show lack of power. throttle completely. At this point you should shift to 2.
  • Page 56 5. Park the motorcycle on a firm,  WARNING flat surface where it will not fall over. Hard braking on wet, loose, 6. Turn the ignition switch to the rough, or other slippery sur- “OFF” position. faces can cause wheel skid 7.

  • Page 57: Carrying A Passenger

    CARRYING A PASSENGER Before you invite someone to be a passenger on your motorcycle, you need to be thoroughly familiar with motorcycle operation. Adjust tire pressures and suspension according to the Tire Pressure and Loading section and the Sus- pension section of this manual. The passenger should always hold onto your waist or hips, or onto the seat strap or grab bar, as...

  • Page 58: Accessory Use And Motorcycle Loading

    ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE ....................6-2 ACCESSORY INSTALLATION GUIDELINES ............ 6-2 LOADING LIMIT ....................6-3 LOADING GUIDELINES ..................6-4 MODIFICATION ....................6-4...

  • Page 59: Accessory Use

    It is not possible center of gravity as is feasible. for Suzuki to test each accessory Check that mounting on the market or combinations of brackets and other attach- all the available accessories;...

  • Page 60: Loading Limit

    • Additional electrical accesso- LOADING LIMIT ries may overload the existing  WARNING electrical system. Severe over- loads may damage the wiring Overloading or improper load- harness or create a hazardous ing can cause loss of motorcy- situation due to the loss of cle control and an accident.

  • Page 61: Loading Guidelines

    Suzuki’s limited warranties may • Keep cargo weight low and as not cover damage caused by close to the center of the modifications that would change motorcycle as possible.
  • Page 62 INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ................7-2 TOOLS ......................... 7-6 GENERAL LUBRICATION .................. 7-6 BATTERY ......................7-7 AIR CLEANER ....................7-10 SPARK PLUG ....................7-13 ENGINE OIL ....................... 7-17 ENGINE IDLE SPEED INSPECTION ..............7-22 THROTTLE CABLE ADJUSTMENT ..............7-22 FUEL HOSE .......................

  • Page 63: Inspection And Maintenance

    (*). You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, ask your Suzuki dealer to do the maintenance.
  • Page 64 Breathing carbon monoxide can cause death or When replacing parts on your severe injury. vehicle, use only genuine Suzuki replacement parts or Never start the engine or let it their equivalent. run indoors or where there is little or no ventilation.
  • Page 65 * Evaporative emission control system (California model only) Replace vapor hose every 4 years * PAIR (air supply) system – – – “SUZUKI SUPER LONG LIFE Replace every 4 years or 48000 km (29000 miles) COOLANT” (Blue) “SUZUKI LONG * Engine coolant LIFE COOLANT”...
  • Page 66 Interval months 1000 6000 12000 18000 24000 Element miles 4000 7500 11000 14500 * Brakes ( 7-29) – Brake hose ( 7-29) * Replace every 4 years – Brake fluid ( 7-29) * Replace every 2 years Tires ( 7-35) –...

  • Page 67: Tools

    TOOLS A tool kit is provided with your motorcycle. The toolbox is located on the left side of the motorcycle. To open the toolbox, refer to the SUSPENSION ADJUSTMENT section. GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and a long ...

  • Page 68: Battery

    • If you cannot charge the bat-  WARNING tery, consult your authorized Suzuki dealer. Wiping the battery with a dry cloth can cause a static elec-  WARNING tricity spark, which can start a fire.
  • Page 69 Battery Removal To remove the battery, follow the procedure below: 1. Place the motorcycle on the side stand. 4. Remove the bolts 3 and front seat 4. 2. Remove the bolt 1. 5. Disconnect the negative (–) terminal 5. 6. Remove the cap. Disconnect the positive (+) terminal 6.
  • Page 70 Suzuki dealer. NOTE: • Select the same type MF bat- tery when replacing the bat- tery.

  • Page 71: Air Cleaner

    AIR CLEANER NOTICE The air cleaner element must be kept clean to provide good engine Failure to inspect the air power and gas mileage. If you use cleaner element frequently if your motorcycle under normal low the vehicle is used in dusty, stress conditions, you should ser- wet, or muddy conditions can vice the air cleaner at the intervals...
  • Page 72 Air Cleaner Element Removal 1. Place the motorcycle on the side stand. 4. Disconnect the tube 5 and coupler 6. 2. Loosen the clamp bolt 1. 5. Remove the screws. Remove the air cleaner case 7. 3. Remove the bolts 2 and unhook the hook 3.
  • Page 73 8. Reinstall the air cleaner ele- ment in reverse order of removal. Be sure that the air cleaner element is securely in position properly sealed. NOTICE Failure to position the air cleaner element properly can 7. Carefully use an air hose to blow the dust from the air allow dirt to bypass the air cleaner element.

  • Page 74: Spark Plug

    Use one of the spark plugs listed or their equivalent. Con- sult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage. 7-13...
  • Page 75 3. Remove the bolt and air cleaner bracket 1. NOTE: If the above-named plugs are not available, consult your authorized Suzuki dealer. NOTE: This motorcycle uses a resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interfer- ence with your motorcycle’s igni-...
  • Page 76 FRONT REAR FRONT (California model) REAR (California model) 5. Pull off the spark plug caps. 6. Remove the spark plugs with a spark plug wrench. 7-15...
  • Page 77 SPARK PLUG CLEANING Installation NOTICE Improper installation of the spark plug can damage your 0.8 – 0.9 mm motorcycle. An overly-tight or (0.031 – 0.035 in) cross-threaded spark plug will 0.6 – 0.7 mm damage the aluminum threads (0.024 – 0.028 in) of the cylinder head.

  • Page 78: Engine Oil

    ENGINE OIL NOTICE Engine life depends on oil amount and quality. Daily engine oil level Operating the motorcycle with checks and periodic changes are too little or too much oil can two of the most important mainte- damage the engine. nance items to be performed.
  • Page 79 ENGINE OIL AND FILTER  CAUTION CHANGE Change the engine oil and oil filter Hot engine oil and exhaust at the scheduled times. The pipes can burn you. engine should always be warm when the engine oil is changed so Wait until the engine oil drain the engine oil will drain easily.
  • Page 80 Do not use the electric starter switch during engine 4. Turn the oil filter 4 with a replacement work. Suzuki “cap type” oil filter wrench or a “strap type” filter NOTE: wrench of the proper size and • Recycle or properly dispose of remove the oil filter.
  • Page 81 Tighten the filter 2 turns or to specified torque. Be sure to use a genuine Suzuki oil filter or an equiva- 8. Mark the top dead center posi- lent one designed for your tion on the “cap type” filter wrench or on the oil filter.
  • Page 82 NOTE: If you do not have a proper oil filter wrench, have your autho- rized Suzuki dealer or a qualified NOTICE mechanic perform this service. Engine damage may occur if you use oil that does not meet Suzuki’s specifications.

  • Page 83: Engine Idle Speed Inspection

    1000 – 1200 r/min when the engine is warm. NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. 2.0 – 4.0 mm (0.08 – 0.16 in) To adjust the cable play: 1.

  • Page 84: Fuel Hose

    Throttle Cable Boots FUEL HOSE Fuel Tank Lift 1. Place the motorcycle on the side stand. Remove the seat by referring to the BATTERY section. The throttle cable has a boots. Check that the boots are fit securely. Do not apply water directly to the boots when wash- ing.
  • Page 85 NOTE: Lifting up the fuel tank too much can result in the fuel hose becoming bent or twisted. Lift the fuel tank as little as possible and disconnect the fuel hose. The fuel tank in the above illustration is lifted to show the fuel hose and coupler clearly.

  • Page 86: Clutch Adjustment

    CLUTCH ADJUSTMENT Major Adjustment Clutch cable play should be 10 – 15 mm (0.4 – 0.6 in) measured at the clutch lever end. Adjust clutch cable play according to the follow- ing procedure: Minor Adjustment 1. Loosen the lock nuts 3. Turn the lock nuts 3 counterclock- wise.

  • Page 87: Engine Coolant

    ENGINE COOLANT Coolant level 3. Loosen the lock nut 6. 4. Turn in the adjuster 7 until it stops. Turn back the adjuster engine coolant solution 7 1/4 turns. should be between “F” (full) and 5. Hold the adjuster 7 with a “L”...
  • Page 88 Radiator Hose Inspection through the filler hole. Inspect the radiator hoses for cracks, damage or engine coolant leakage. If any defects are found, ask your Suzuki dealer to replace the radiator hose with a new one. 7-27...

  • Page 89: Final Gear Oil

    FINAL GEAR OIL  WARNING Change the gear oil as follows: 1. Place the motorcycle on the Operating the motorcycle with side stand. too little final gear oil can cause the final drive unit to lock up and cause an accident. Check for leaks and the correct level of final gear oil before each use.

  • Page 90: Brakes

    Inspect the brake hoses and hose Replace the brake fluid every joints for cracks, damage or brake fluid leakage. If any defects are two years to maintain braking found, ask your Suzuki dealer to performance. replace the brake hose with a new one. 7-29...
  • Page 91 Wipe spilled fluid up ing. Use only DOT4 brake fluid immediately. from a sealed container. Never use or mix with different types NOTE: SUZUKI highly recom- of brake fluid. mends the use of ECSTAR brand brake fluid. ECSTAR has been specially...
  • Page 92 If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and main- tain the brake pads as recom- mended.  WARNING...
  • Page 93 NOTE: Do not squeeze the brake Rear Brake Pedal Adjustment lever when the pads are not in  WARNING their positions. It is difficult to push the pistons back into position. Too much play in the rear brake  WARNING pedal can cause poor braking performance and may lead to Replacing only one of the two...
  • Page 94 The rear brake pedal position and 20 – 30 mm (0.8 – 1.2 in) the free travel must be properly adjusted. Adjust the brake pedal in the following manner: 95 – 105 mm (3.7 – 4.1 in) 4. Adjust the free travel to 20 – 30 mm (0.8 –...
  • Page 95 B, have the brake shoes tor on rear brake. To check wear replaced by your authorized of the brake lining perform the fol- Suzuki dealer or a qualified lowing: mechanic. Range Index mark  WARNING...

  • Page 96: Tires

    TIRES  WARNING  WARNING Failure to perform break-in of the tires could cause tire slip The tires on your motorcycle and loss of control, which form the crucial link between could result in an accident. your motorcycle and the road. Failure to take the precautions Use extra care when riding on below may result in an accident...
  • Page 97 Worn tires are susceptible to pressure readings. puncture failures and subsequent loss of motorcycle control. Tire VL800 wear also affects the tire profile, changing motorcycle handling LOAD DUAL RIDING characteristics.
  • Page 98 • Ask your Suzuki dealer or a qualified mechanic to per- form tire repair, replacement, balancing because proper tools and experience are required.

  • Page 99: Side Stand/Ignition Interlock System

    If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- properly. Have your motorcycle inspected authorized Suzuki dealer or some other qualified service mechanic. 7-38...

  • Page 100: Front Wheel Removal

    1. Loosen the axle 2 temporarily. NOTE: A special tool is necessary to loosen the axle. The special tool is available at your Suzuki dealer. 5. Remove the speed sensor 3. 3. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end.
  • Page 101 NOTE: Never squeeze the front use one, ask your authorized brake lever with wheel Suzuki dealer to check the removed. It is very difficult to force bolts and nuts. the pads back into the caliper assembly. Front axle tightening torque: 65 N·m (6.5 kgf-m, 47.0 lbf-ft)

  • Page 102: Rear Wheel Removal

    REAR WHEEL REMOVAL NOTICE Removing the rear wheel with- out use of an accessory stand can result in your motorcycle falling over and being dam- aged. attempt roadside removal of the rear wheel. Only remove the rear wheel at a properly equipped servicing facility using an accessory ser- vice stand.
  • Page 103 Be sure to tighten the bolts and nuts to the specified torque. If you do not have a torque wrench or do not know how to use one, ask your authorized Suzuki dealer to check the 6. Draw out the axle 8. bolts and nuts. 7-42...

  • Page 104: Light Bulb Replacement

    50 N·m (5.0 kgf-m, 36.0 lbf-ft) Failure to use a light bulb with the correct wattage rating can NOTE: Apply a drop of SUZUKI overload the electrical system THREAD LOCK “1322D” to the of your motorcycle or cause rear frame mounting bolt 1, 2.
  • Page 105 Headlight To replace the headlight bulb, per- form the following steps: 3. Disconnect the socket 3 from the headlight and remove the rubber cap 4. 1. Remove the right and left bolts. Unhook hooks. Remove the headlight cover 4. Unhook the bulb holder spring 5, and pull out the bulb 6.
  • Page 106 Headlight Beam Adjustment Turn Signal Light The headlight beam can be adjusted both up and down or right and left if necessary. 1. Remove the screw 1. 2. Turn the lens counterclockwise and remove it. To adjust the beam up and down: Turn the adjuster 1 clockwise or counterclockwise.

  • Page 107: Fuses

    If a blown fuse is found, then the electrical problem must inspected and repaired before replacing the blown fuse with a new fuse. Consult your Suzuki 1. Turn the license plate lens dealer for the electrical system counterclockwise and remove check and repair. WARNING...
  • Page 108 MAIN FUSE FUSE LIST • 30A MAIN fuse protects all electrical circuits. • 10A HEAD-HI fuse protects the speedometer and head- light high beam. • 10A HEAD-LO fuse protects the headlight low beam. • 10A FUEL fuse protects the ECM, fuel pump, injectors and speedometer.

  • Page 109: Catalytic Converter

    CATALYTIC CONVERTER  WARNING The purpose of the catalytic con- verter is to minimize the amount If you park or operate the of harmful pollutants in your motorcycle in areas where motorcycle’s exhaust. there are combustible materi- leaded fuel motorcycles als such as dry grass or leaves, equipped with catalytic converters these materials may come in...
  • Page 110 NOTICE Improper motorcycle opera- tion can cause catalyst or other motorcycle damage. To avoid damage to the catalyst or other related components, you should take the following precautions: • Maintain the engine in the proper operating condition. • In the event of an engine mal- function, particularly involving engine misfire or...

  • Page 112: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..................8-2 IGNITION SYSTEM CHECK ................8-3...
  • Page 113 NOTICE ble in the fuel injection system, Improper repairs or adjust- take your machine to an autho- rized Suzuki dealer. Refer to the ments may damage the motor- “INSTRUMENT PANEL” section cycle instead of fixing it. Such for an explanation of the fuel damage may not be covered injection system indicator.
  • Page 114 If there is no spark, take tem, take your machine to an your machine to your autho- authorized Suzuki dealer. rized Suzuki dealer or a quali- Refer to the “INSTRUMENT fied mechanic. PANEL” section for an explana- tion of the fuel injection system indicator.

  • Page 116: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................9-2 PROCEDURE FOR RETURNING TO SERVICE ..........9-3 CORROSION PREVENTION ................9-3 MOTORCYCLE CLEANING ................9-4 INSPECTION AFTER CLEANING ............... 9-7...

  • Page 117: Storage Procedure

    3. Cover the air cleaner intake equipment and skill. For this rea- and the muffler outlet with oily son, Suzuki recommends that you rags to prevent humidity from trust this maintenance work to entering. your authorized Suzuki dealer. If...

  • Page 118: Procedure For Returning To Service

    PROCEDURE FOR RETURNING CORROSION PREVENTION TO SERVICE It is important to take good care of your motorcycle to protect it from 1. Clean the entire motorcycle. corrosion and keep it looking new 2. Remove the oily rags from the for years to come. air cleaner intake and muffler outlet.

  • Page 119: Motorcycle Cleaning

    Do not use gone through to the bare hard materials which metal, have a Suzuki dealer scratch the paint. make the repair. 2. Wash the entire motorcycle • Store your motorcycle in a dry, with a mild detergent or car well-ventilated area.
  • Page 120 NOTE: The headlight lens can be NOTICE fogged after washing the motorcy- cle or riding in the rain. Headlight High pressure washers such as fogging will be cleared gradually those found at coin-operated when the headlight is turned on. car washes have enough pres- When clearing the headlight lens sure to damage the parts of fogging, run the engine to avoid...
  • Page 121 PLASTIC PARTS SPECIAL CARE FOR MATTE Plastic parts such as headlight FINISH PAINT lens and speedometer display, Do not use polishing compounds are easy to be damage. When or waxes that contain polishing such part is cleaned, wash it compounds on surfaces which using water after cleaning it using have a matte finish.

  • Page 122: Inspection After Cleaning

    INSPECTION AFTER CLEANING For extended life of your motorcy- cle, lubricate it according to the LUBRICATION POINTS section.  WARNING Operating the motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes.
  • Page 124 CONSUMER INFORMATION WARRANTIES ....................10-2 EMISSION CONTROL SYSTEMS ..............10-3 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-4 SERIAL NUMBER LOCATION ................10-5 REPORTING SAFETY DEFECTS ..............10-6 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....10-7 LOCATION OF LABELS ................... 10-8 10-1...

  • Page 125: Consumer Information

    CONSUMER Suzuki limited warranties and the Federal and California Emission INFORMATION Control System Limited Warranty may not cover damage caused by WARRANTIES modifications that would change The warranties for your motorcy- the original vehicle specifications cle are explained in a separate...

  • Page 126: Emission Control Systems

    If parts tions set specific standards for replacement is necessary, replace exhaust emission output levels the parts with Genuine Suzuki and fuel permeation emissions, parts or their equivalent. Installing as well as particular servicing improper replacement parts or requirements.

  • Page 127: Tampering With Noise Control System Prohibited

    • removing or puncturing the air cleaner case, cleaner cover, baffles, or any other component which conducts intake air. Whenever replacing parts on your motorcycle, Suzuki recommends that you use genuine Suzuki replacement parts or their equiva- lent. 10-4...

  • Page 128: Serial Number Location

    Frame No: documents for your motorcycle. You also need these numbers to help your authorized Suzuki Engine No: dealer when you order parts. The frame number 1 is stamped on the steering head as shown in the illustration. The engine serial number 2 is stamped on the crankcase assembly.

  • Page 129: Reporting Safety Defects

    REPORTING SAFETY DEFECTS To contact Suzuki Motor of Amer- ica, Inc., owners in the continental If you believe that your vehicle United States can call toll-free 1- has a defect which could cause a 800-444-5077, or write to: Suzuki crash or could cause injury or Motor of America, Inc.

  • Page 130: On-Board Motorcycle Computer Data Information

    In addi- tion, once Suzuki collects or receives data, Suzuki may use the data for research conducted by Suzuki, make the data avail- able for outside research if need is shown and confidentiality is assured, or make summary data...

  • Page 131: Location Of Labels

    The owner’s manual contains important safety information and instructions which should be read carefully before operating the vehicle. If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. 10-8...
  • Page 132 3 (VL800) SOLO RIDING DUAL RIDING COLD TIRE PRESSURE kgf/cm kgf/cm FRONT 2.00 2.00 REAR 2.50 2.50 FRONT REAR TIRE SIZE 130/90-16M/C 67H 170/80-15M/C 77H GS-23F GS-23R TYPE 3 (VL800T) DUAL RIDING SOLO RIDING COLD TIRE PRESSURE kgf/cm kgf/cm FRONT 2.25...
  • Page 133 SUZUKI MOTOR CORPORATION DISPLACEMENT : V E H I C L E E M I S S I O N C O N T R O L I N F O R M A T I O N ENGINE FAMILY :...

  • Page 135: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2500 mm (98.4 in) Overall width............ 955 mm (37.6 in) Overall height ..........1110 mm (43.7 in) Wheelbase ............1655 mm (65.2 in) Ground clearance..........140 mm (5.5 in) Seat height ............700 mm (27.6 in) Curb mass ............
  • Page 136 ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK DPR7EA-9 or DENSO X22EPR-U9 NGK DR7EA or DENSO X22ESR-U ... California Battery .............12V 36kC (10Ah)/10HR Generator ............Three-phase A.C. Generator Main fuse............30A Fuse ..............20/10/10/10/10/10A Headlight ............12V 60/55W (H4) Brake light/Taillight...........LED License plate light..........12V 5W Front turn signal light ........12V 21/5W Rear turn signal light ........12V 21W Speedometer light ...........LED...
  • Page 137 INDEX ACCESSORIES AND EMISSION CONTROL LOADING....... 1-6 SYSTEMS ......10-3 ACCESSORY INSTALLATION ENGINE COOLANT .....7-26 GUIDELINES......6-2 ENGINE COOLANT ACCESSORY USE ....6-2 SOLUTION ......2-6 AIR CLEANER ..... 7-10 ENGINE IDLE SPEED INSPECTION......7-22 ENGINE OIL ....2-4 7-17 BATTERY....... 7-7 BE EXTRA SAFETY- CONSCIOUS ON BAD FINAL GEAR OIL ....7-28...
  • Page 138 IF A COLLISION IS IMMINENT, MAINTENANCE DO SOMETHING! ....1-3 SCHEDULE ......7-2 IF YOU DON’T HAVE A HELMET MODIFICATION .....6-4 - BUY A HELMET, AND WEAR IT MOST ACCIDENTS CAN BE EVERY TIME YOU RIDE ..1-3 AVOIDED.......1-2 IGNITION SWITCH ....3-5 MOTORCYCLE IGNITION SYSTEM CLEANING ......9-4...
  • Page 139 REAR BRAKE PEDAL ..3-19 TAMPERING WITH NOISE REAR WHEEL CONTROL SYSTEM REMOVAL......7-41 PROHIBITED......10-4 REPORTING SAFETY THROTTLE CABLE DEFECTS......10-6 ADJUSTMENT .....7-22 RIDING ON HILLS ....5-6 TIRES ........7-35 RIGHT HANDLEBAR ... 3-16 TOOLS ........7-6 SERIAL NUMBER USING THE LOCATION ......

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