Suzuki VZR1800K6 Service Manual
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Suzuki VZR1800K6 Service Manual

Suzuki VZR1800K6 Service Manual

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Assembly and Pre-Delivery
Service Guide
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This service guide has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this service guide carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2)
categories could lead to serious problems.
areas are denoted to emphasize certain areas and carry the following meanings:
Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the
dealer shall be deemed by your Suzuki distributor to be performed at the dealer's
sole risk and responsibility. The Suzuki distributor disclaims any and all liability,
obligation or responsibility for any defects resulting from said assembly and pre-
delivery set-up, and for any claims, demands or causes of action for damage to
property or for personal injuries resulting from the Dealer's assembly and pre-
delivery set-up of Suzuki motorcycle.
This Assembly and Pre-Delivery Service Guide may contain photographs of
products sold in other markets. The assembly and pre-delivery service procedures
in this guide, however, apply to this market.
K6
FOREWORD
. . . . . . . Indicates a potential hazard that could result in
death or injury.
. . . . . . . . . . Indicates a potential hazard that could result in
motorcycle damage.
and
99505-01096-03E
January '06 Printed in Japan (TK) 03

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  • Page 1 Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the dealer shall be deemed by your Suzuki distributor to be performed at the dealer’s sole risk and responsibility. The Suzuki distributor disclaims any and all liability,...
  • Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
  • Page 3 Remove the bolts of the bracket. A: Bolt Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle. Handling crates requires two operators.

  • Page 4: Location Of Parts

    LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Handlebars assembly Rear view mirror Right and Left Clamp Frame body cover Right and Left Allen bolt 8 ×...
  • Page 5 The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly C: Left switch Clutch cable...

  • Page 6: Removing The Bracket

    The certification of vehicle pre-delivery form must be filled out in duplicate for every motorcycle. Use of this form is mandatory and serves as pro- tection for yourself and your customer, as well as assuring that all necessary assembly and service functions have been completed.
  • Page 7 Install the handlebars assembly using the two clamps and four bolts. NOTE: The punch mark on the clamps shows front side. Align the dot mark on the handlebars with the mating surface of the front side of left clamp. A: Clamp B: 8 ×...

  • Page 8: Front Brake Master Cylinder

    THROTTLE Insert the boss of the throttle housing into the hole on the handlebars. Tighten the throttle assembly with two screws. Check to ensure that the throttle operates freely and closes automatically. A: Boss B: Hole C: 5 × 45 mm screw D: 5 ×...

  • Page 9: Left Switch

    Connect the front brake light switch lead wires coupler to the brake light switch. A: Front brake light switch B: Lead wire coupler LEFT SWITCH Insert the boss of the left switch holder into the hole on the handlebars. Tighten the left switch assembly with the two screws. Be careful not to pinch the wiring harness between the housing and holder.

  • Page 10: Clutch Cable

    CLUTCH CABLE Pass the clutch cable through the lever cover. A: Clutch cable B: Clutch lever cover Turn the clutch cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess in the clutch lever, then pull on the outer cable housing and insert it into the adjuster.
  • Page 11 LEFT Clamp the handlebar left switch wiring harness, clutch cable and tachometer lead wire with strap. OUTSIDE NOTE: Cut the remaining of the strap as shown in the photograph. A: Strap L:140 mm B: Left switch wiring harness C: Clutch cable D: Tachometer lead wire OUTSIDE Clamp the throttle cable to the headlight stay with O-...
  • Page 12 Remove the crate axle bracket from the crate base. NOTE: The bracket and bolts are no longer needed and these may be discarded. A: Crate axle bracket B: Bolt 1. Lift the front of motorcycle by using a hoist. 2. Raise the rear of motorcycle. 3.
  • Page 13 Remove the screws. Remove the frame covers. A: Frame cover FORWARD B: Allen screw C: Boss D: Hook (Frame cover) E: Rubber cushion (Fuel tank) Remove the fuel tank fitting bolt. Slide the fuel tank backward a little. A: Fuel tank B: Bolt Remove the screws.
  • Page 14 RIGHT Fix the frame body cover to the frame body upper cover assembly with screw. (Right) A: Frame body cover B: Frame body upper cover C: Guide D: Hole E: Hook F: Click G: 5 × 16 mm tapping screw LEFT Fix the frame body cover to the frame body upper cover assembly with screw.
  • Page 15 RIGHT Fit the frame body cover assembly (Right) to the frame body lower cover assembly. A: Frame body lower cover assembly B: Frame body cover assembly (Right) C: Guide D: Hole E: Boss F: Hole (rubber cushion) G: Hook Fix the frame body cover assembly (Right) to the frame body lower cover assembly with fastener.
  • Page 16 LEFT RIGHT Install the recess of frame body lower cover to the boss of frame. A: Recess (Frame body lower cover) B: Boss (Frame) RIGHT Install the fastener by pushing. A: Fastener (Large) B: Boss (Frame) Install the frame body cover assembly. Pass the throttle cable (Pulling) through over the boss of frame body head cover.

  • Page 17: Front Fender

    Tighten the screws. Install the fastener. NOTE: To install the fastener, pull the center pin and fix the fastener by pushing the center pin. A: Stepped Allen screw B: Fastener (Small) Reinstall the fuel tank. Reinstall the frame cover. Reinstall the seat. Insert the seat hook into the seat hook retainer and push down the seat firmly.

  • Page 18: Brake Disc

    FRONT REAR BRAKE DISC To prevent brake squeaking and pad contamination, carefully clean the front and rear brake disc plates with alcohol or other non-petroleum based solvent. This will remove the rust-preventive coating and dirt. FRONT WHEEL When installing the front wheel onto the axle, special attention must be paid to the arrow of the rotational direction on the tire sidewall.
  • Page 19 Temporarily remove the left front brake caliper. Do not remove the supporter inserted between the brake pads until the brake caliper is installed. A: Supporter B: Brake caliper (Left) C: Caliper mounting bolt Remove the supporter from the brake pad of the right front brake caliper.
  • Page 20 Insert the front axle from the right side of fork leg and fix the front wheel assembly to the front fork. When install the front axle, be careful not to scratch the oil seal lip. Never use force to install the front axle. If it cannot be installed by hand, it is not cor- rectly aligned.

  • Page 21: Front Brake Caliper

    FRONT BRAKE CALIPER Remove the supporter from the brake pad of the left front brake caliper. A: Supporter B: Brake caliper Set the front brake caliper so the brake disc plate is inserted between two brake pads. Install the front brake caliper. Be careful not to scratch the front wheel.

  • Page 22: Rear View Mirror

    Place the motorcycle on the side stand, then remove the hoist hook. REAR VIEW MIRROR Install the rear view mirror and tighten lock nuts securely after positioning them properly. NOTE: Fix the mirror in the position so as to secure rear view.

  • Page 23: Seat Tail Cover

    REFLEX REFLECTOR (LEFT) Align the boss of reflex reflector to the hole of bracket. Install the reflex reflector to the bracket. A: Reflex reflector B: Bracket C: Boss D: Hole E: Mark “L” F: 5 mm nut Remove the bolt. Install the reflex reflector assembly to the frame with bolt.

  • Page 24: Removing The Tape

    REMOVING THE TAPE Remove the tapes from the muffler and cover. A: Tape B: Muffler C: Cover OWNER’S MANUAL Remove the seat using the key. Store the owner’s manual in place. A: Owner’s manual...
  • Page 25 SERVICING BATTERY The battery is located under the seat. Remove the seat using the key. Pull the fastener knob. Remove the battery holder lid. Remove the battery from the motorcycle. A: Battery holder lid B: Fastener Filling electrolyte Remove the aluminium tape sealing the battery elec- trolyte filler holes.
  • Page 26 With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. A: Electrolyte containers Make sure air bubbles are coming up in each electro- lyte container, and leave in this position for about 20...
  • Page 27 After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes. Insert the caps into the filler holes, pressing in firmly so that the top of the each caps does not protrude above the upper surface of the battery’s top cover.

  • Page 28: Brake Fluid

    1. Reinstall the battery in the motorcycle. 2. First connect the + lead to the + positive terminal of the battery. 3. Cover + terminal with rubber boot. 4. Connect the - lead to the - negative terminal of the battery. A: + lead B: - lead C: Rubber boot...
  • Page 29 FRONT BRAKE AIR BLEEDING Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever or brake pedal feels spongy or weak, then most likely there is air in the hydraulic circuit. To bleed the air from the front brake, use the following procedure: 1.

  • Page 30: Front Brake Lever

    FRONT BRAKE LEVER Make sure the front brake lever position is correct. The standard setting for this motorcycle is as indicated in the table below. Standard setting A: Adjuster THROTTLE CABLE This motorcycle has a twin throttle cable system. Cable A is for pulling cable and cable B is for return- ing.
  • Page 31 CLUTCH CABLE Check the clutch lever play at the clutch lever end when the lever is lightly pulled in towards the grip. Clutch lever play: 10–15 mm (0.4–0.6 in) NOTE: Minor adjustments can now be made with the clutch lever adjuster A. If adjustment is necessary, carry out the procedure below: 1.

  • Page 32: Rear Brake Pedal

    REAR BRAKE PEDAL Check the rear brake pedal height. Rear brake pedal height: 25–35 mm (1.0–1.4 in) If the rear brake pedal height is not correct, adjust in the following manner: 1. Loosen the lock nut A. 2. Rotate the push rod B to locate the pedal to the correct height above the top face of the footrest C.

  • Page 33: Headlight Beam Adjustment

    HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted both horizontally and vertically if necessary. To adjust the beam horizontally: Turn the adjuster A clockwise or counterclockwise. To adjust the beam vertically: Turn the adjuster B clockwise or counterclockwise. ENGINE COOLANT The engine coolant level should be kept between the “FULL”...

  • Page 34: Engine Oil

    Oil quality is a major contributor to your engine’s per- formance and life. JASO Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFOR- 10W-40 SF or SG – MANCE 4 MOTOR OIL or equivalent engine oil.
  • Page 35 ENGINE OIL VISCOSITY RATING SELECTION CHART SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the following chart.

  • Page 36: Idle Speed Adjustment

    Engine idle speed: 800–1 000 r/min NOTE: If the engine idle speed is not within the speci- fied range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. FUEL Use only premium unleaded gasoline of at least 90 pump octane (R/2+M/2 method) or 95 octane or higher rated by the research method.

  • Page 37: Tightening Torque

    TIGHTENING TORQUE Item Part Name N·m kgf-m lb-ft Item Part Name N·m kgf-m lb-ft FRONT FORK AXLE Handlebar clamp bolt 16.5 Front axle 10.0 72.5 Steering stem head nut 65.0 Rear axle nut 10.0 72.5 Handlebar holder bolt 61.5 ABSORBER Front fork upper bracket bolt 16.5 Rear shock absorber nut (Front)

  • Page 38: Harness Routing

    HARNESS ROUTING Clamp Wiring harness Clamp Clamp Set the speedometer wiring harness to the right side. Wiring harness Clamp Clamp Be careful not to pinch the wiring harness Frame between the fuel tank and frame. Wiring harness Clamp Clamp Wiring harness Clamp Clamp Speed sensor lead wire...
  • Page 39 Pass the handlebar switch lead wire through upper the brake switch coupler. Clamp Clamp Handlebar switch lead wire (R) Handlebar switch lead wire (L) Tachometer lead wire Front brake hose Clutch cable Clamp High tension cord Pass the wiring harness through Wiring harness upper the breather hose.

  • Page 40: Cable Routing

    CABLE ROUTING Pass the throttle cable through between the handlebar and brake hose. Front brake hose Throttle cable (Returning cable) Throttle cable must be passed under the handlebar switch lead wire and brake switch coupler. VIEW A Cable guide Throttle cable (Pulling cable) Throttle cable (Returning cable) Clutch cable Throttle cable (Pulling cable)

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