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VL800/C/ T
OWNER'S MANUAL
This owner's manual contains
important safety information.
Please read it carefully.

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Table of Contents

Troubleshooting

   Also See for Suzuki VL800

   Summary of Contents for Suzuki VL800

  • Page 1 VL800/C/ T OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully.
  • Page 2 California Proposition 65 Warning WARNING Engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator.
  • Page 3 NOTE: Indicates special informa- instructions closely to ensure tion to make maintenance easier emission compliance. Your autho- or instructions clearer. rized Suzuki dealer has experi- enced technicians that are trained WARNINGs and CAUTIONs are to provide your machine with the arranged like this: best possible service with the right tools and equipment.
  • Page 4 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 5: 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 7: 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 8: Most Accidents Can Be Avoided

    MOST ACCIDENTS CAN BE THE SPORT OF AVOIDED MOTORCYCLING 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 9: If You Don't Have Ahelmet - 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 10: 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 11: Be Extra Safety-conscious On Bad Weather Days

    Riding motorcycle safely PRACTICE AWAY FROM requires that your mental and TRAFFIC physical skills are fully part of the Your riding skill and your mechan- experience. should ical knowledge form the founda- attempt to operate a motor vehi- tion for safe riding practices. We cle, especially one with two suggest that you practice riding wheels, if you are tired or under...
  • Page 12: Carrying A Passenger

    This manual can increase your mental or advanced riding skills riding enjoyment and safety. You course nearest you, or owners in should read it thoroughly. the USA can call toll-free 1-800- 446-9227. Good riding on your new Suzuki!
  • Page 13: Fuel, Oil And Coolant Recommendations

    FUEL, OIL AND COOLANT RECOMMENDATIONS FUEL ........................2-2 ENGINE OIL ......................2-3 GEAR OIL ......................2-4 ENGINE COOLANT SOLUTION ................. 2-5...
  • Page 14: Fuel

    Suzuki and may Oxygenated fuels which meet the minimum octane requirement and not be covered under the New...
  • Page 15: Engine Oil

    • Be sure that any oxygenated engine oil. Suzuki recommends fuel you use has octane rat- the use of SUZUKI PERFOR- ings of at least 87 pump MANCE 4 MOTOR OIL or equiva- octane ((R+M)/2 method). lent engine oil. Use oil with an API •...
  • Page 16: Gear Oil

    JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle oils. Some engine oils which have engines. Motorcycle and ATV an API classification of SH or...
  • Page 17: Engine Coolant Solution

    ENGINE COOLANT SOLUTION CAUTION Use engine coolant that is com- patible with an aluminum radiator, Spilled engine coolant can mixed with distilled water at a damage painted surfaces. 50:50 mixture ratio for engine coolant solution. An engine cool- Do not spill any fluid when fill- ant mixture other than 50:50 can ing the radiator.
  • Page 19: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 KEY ........................3-5 IGNITION SWITCH ....................3-5 INSTRUMENT PANEL ..................3-7 LEFT HANDLEBAR ................... 3-13 RIGHT HANDLEBAR ..................3-15 FUEL TANK CAP ....................3-17 GEARSHIFT LEVER ..................3-18 REAR BRAKE PEDAL ..................3-18 HELMET HOLDER ....................
  • Page 20: 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 21 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 VL800C G Fuses H Passenger footrests VL800T...
  • Page 22 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 VL800C VL800T...
  • Page 23: 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. An identifying number is stamped on the plate. Use this “OFF” position number when making a replace- All electrical circuits are cut off.
  • Page 24 “P” (PARKING) position The key hole can be covered by turning the lid. The taillight will come on to increase visibility for temporary road side parking at night. The key can be removed and the steering will be locked.  WARNING Turning the ignition switch to the “P”...
  • Page 25: Instrument Panel

    INSTRUMENT PANEL GEAR SPEEDOMETER 1 The speedometer indicates the road speed in kilometers per hour and miles per hour. TURN SIGNAL INDICATOR LIGHT “” 2 When the turn signals are being operated either to the right or to the left the indicator will flash at the same time.
  • Page 26 Check the oil level and determine if the proper amount of oil is in the engine. If the light still does not go out, have your authorized SUZUKI dealer or a qualified mechanic troubleshoot your motorcycle.
  • Page 27 “FI”, have your autho- rized Suzuki dealer or a A. The display 7 indicates “FI” qualified mechanic inspect the intermittently, and the red indi-...
  • Page 28 COMBINATION SYSTEM DISPLAY 7 The display has five functions, clock, odometer, two trip meters and gear position. When the igni- tion switch is turned to the “ON” position, the display indicates the test pattern shown below for two seconds. GEAR GEAR When display...
  • Page 29 To change the display, push the Clock button 8. The display changes in The clock has a 12-hour display. the order below. Follow the procedure below to adjust the clock. 1. Push the buttons, 8 and 9, simultaneously for 2 seconds GEAR until the hour display blinks.
  • Page 30 FUEL METER “” 0 The fuel meter indicates the amount of fuel remaining in the fuel tank. The fuel meter displays all 5 segments when the fuel tank is full. The segment comes on when the fuel level drops below 3.5 L (3.7 US qt).
  • Page 31: Left Handlebar

    Dimmer Switch 3 LEFT HANDLEBAR “” position The headlight low beam and tail- light turn on. “” position The headlight high beam and tail- light turn on. The high beam indi- cator light also turns on. CAUTION Clutch Lever 1 Holding the dimmer switch The clutch lever is used for disen- between “”...
  • Page 32 Horn Button “” 5 Press the button to sound the horn. Hazard Warning Switch “” 6 All four turn signal lights and indi- cators will flash simultaneously when the switch is turned on with the ignition switch in the “ON” or “P”...
  • Page 33: 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 34 CAUTION To prevent electrical system damage, do not operate the starter motor longer than five seconds at a time. If the engine does not start after several attempts, check Electric Starter Button “” 3 the fuel supply and ignition Use this button to operate the system.
  • Page 35: Fuel Tank Cap

    FUEL TANK CAP  WARNING Overfilling the fuel tank can cause the fuel to overflow when it expands due to heat from the engine or the sun. Spilled fuel can catch on fire. Never fill the fuel above the bottom of the filler neck. To open the fuel tank cap, insert the ignition key into the lock and ...
  • Page 36: 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, pull the light will come on when the rear clutch lever and close the throttle brake is operated.
  • Page 37: 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 38: Suspension Adjustment

    SUSPENSION ADJUSTMENT  WARNING REAR SUSPENSION Riding with the side stand Spring Pre-load Adjustment incompletely retracted The rear suspension spring pre- result in an accident when you load is adjustable to compensate turn left. for rider, load, riding style and •...
  • Page 39 4. NOTE: Use a hook type spring adjuster or Suzuki spring adjuster, Part number 09822-00003 to adjust the rear suspension spring. 4. Unhook the hooks and remove The Suzuki spring adjuster is the cover.
  • Page 41: Break-in And Inspection Before Riding

    BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-3...
  • Page 42 Breaking in the New Tires BREAK-IN AND 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 43 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 and maintain service your motorcycle will your motorcycle properly receive. During break-in opera- increases the chance of an tion, all of the engine components will have mated together and accident or equipment dam-...
  • Page 44 Check the condition of the motor- WHAT TO cycle to help make sure that you CHECK FOR: CHECK do not have mechanical problems Steering • Smoothness or get stranded somewhere when • No restriction of movement you ride. Before riding the motor- •...
  • Page 45: Riding Tips

    RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF AND SHIFTING ................ 5-3 USING THE TRANSMISSION ................5-4 RIDING ON HILLS ....................5-5 STOPPING AND PARKING ................5-5 CARRYING A PASSENGER ................5-7...
  • Page 46: Starting The Engine

    When the Engine is Warm: RIDING TIPS Close the throttle completely and push the electric starter button. STARTING THE ENGINE Before attempting to start the When a Warm Engine is Hard to engine, make sure: Start: • The transmission is in neutral. Open the throttle 1/8 to 1/4 turn •...
  • Page 47: Starting Off And Shifting

    STARTING OFF AND SHIFTING  WARNING  WARNING Sudden side winds, which can occur when being passed by Riding this motorcycle larger vehicles, at tunnel exits excessive speed increases or in hilly areas, can upset your your chances of losing control control.
  • Page 48: 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 49: Riding On Hills

    RIDING ON HILLS STOPPING AND PARKING • When climbing steep hills, the 1. Turn the throttle grip away from motorcycle may begin to slow you to close the throttle com- down and show lack of power. pletely. At this point you should shift to 2.
  • Page 50 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 51: 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 53: Accessory Use And Motorcycle Loading

    ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE ....................6-2 ACCESSORY INSTALLATION GUIDELINE ............6-2 LOADING LIMIT ....................6-3 LOADING GUIDELINES ..................6-4 MODIFICATION ....................6-4...
  • Page 54: 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 55: 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 this may result electrical power during the operation of the motorcycle.
  • Page 56: Loading Guidelines

    LOADING GUIDELINES MODIFICATION This motorcycle primarily Modification of the motorcycle, or intended to carry small items removal of original equipment when you are not riding with a may render the vehicle unsafe or passenger. Follow the guidelines illegal. Obey all applicable equip- below to carry a passenger or ment regulations in your area.
  • Page 57: Inspection And Maintenance

    INSPECTION AND MAINTENANCE NOTICE ........................ 7-2 MAINTENANCE SCHEDULE ................7-2 TOOLS ......................... 7-5 GENERAL LUBRICATION .................. 7-5 BATTERY ......................7-6 AIR CLEANER ..................... 7-7 SPARK PLUG ....................7-11 ENGINE OIL ....................... 7-15 ENGINE IDLE SPEED INSPECTION ..............7-19 THROTTLE CABLE ADJUSTMENT ..............7-20 FUEL HOSE .......................
  • Page 58: Notice

    (a)(2). Always follow the inspection and maintenance recommen- dations and schedules in this owner’s manual. Ask your SUZUKI dealer or a qualified mechanic to do the mainte- nance items marked with an asterisk (*). You may perform unmarked maintenance...
  • Page 59 Use only genuine SUZUKI re- placement parts or their equiv- Only run the engine outdoors alent. where there is fresh air.
  • Page 60 MAINTENANCE CHART Interval: This interval should be judged by odometer reading or number of months, whichever comes first. Interval 1000 6000 12000 18000 24000 mile 4000 7500 11000 14500 Element months Air cleaner element – * Exhaust pipe bolts and muffler bolts –...
  • Page 61: 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 62: Battery

    BATTERY Battery Removal 1. Place the motorcycle on the The battery is a sealed type bat- side stand. tery and requires no mainte- nance. The standard charging rate is 1.2A × 5 to 10 hours and the maximum rate is 5.0A × 1 hour.
  • Page 63: Air Cleaner

    AIR CLEANER The air cleaner element must be kept clean to provide good engine power and gas mileage. If you use your motorcycle under normal low stress conditions, you should ser- vice the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to inspect the air cleaner 5.
  • Page 64 Air Cleaner Element Removal CAUTION 1. Place the motorcycle on the side stand. Clean or replace the air cleaner element frequently if the motor- cycle is used in dusty, wet or muddy conditions. The air cleaner element will clog under these conditions, and this may cause engine damage, poor performance, and poor fuel...
  • Page 65 4. Disconnect the tube 5 and 7. Carefully use an air hose to coupler 6. blow the dust from the air cleaner element. NOTE: Always apply air pressure to the mesh side of the air cleaner element only. If you apply air pres- sure to the fabric side, dirt will be forced into the pores of the ele- ment, restricting the air flow...
  • Page 66 8. Reinstall the air cleaner ele- Air Cleaner Drain Plug ment in reverse order of removal. Be sure that the air cleaner element is securely in position properly sealed. CAUTION Failure to position the air cleaner element properly can allow dirt to bypass the air Remove the plug and drain water and oil at the periodic mainte- cleaner element.
  • Page 67: Spark Plug

    Use one of the spark plugs lems. Use only the recommended listed below or equivalent. spark plugs. Consult your authorized SUZUKI dealer or a qualified mechanic if you are not sure which spark plug is correct for your type of usage. 7-11...
  • Page 68 Spark Plug Removal 1. Place the motorcycle on the side stand. 2. Remove the air cleaner by referring to the AIR CLEANER section. FRONT 3. Remove the bolt and air cleaner bracket 1. REAR 4. Remove the bolt and open the cover 2.
  • Page 69 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. 7-13...
  • Page 70 SPARK PLUG CLEANING Installation CAUTION A crossthreaded or overtight- ened spark plug will damage 0.8 – 0.9 mm the aluminum threads of the (0.031 – 0.035 in) cylinder head. 0.6 – 0.7 mm (0.024 – 0.028 in) Follow the procedure below to (California) tighten the spark plug properly.
  • Page 71: Engine Oil

    ENGINE OIL CAUTION Engine life depends on oil amount and quality. Daily engine oil level The engine oil level must be checks and periodic changes are between the “L” (Low) line and two of the most important mainte- “F” (Full) line, or engine dam- nance items to be performed.
  • Page 72 ENGINE OIL AND FILTER CHANGE Change the engine oil and oil filter at the scheduled times. The engine should always be warm when the engine oil is changed so the engine oil will drain easily. The procedure is as follows: 1.
  • Page 73 Brief contact with used oil 4. Turn the oil filter with a Suzuki may irritate skin. “cap type” oil filter wrench or a “strap type” filter wrench of the • Keep new and used oil away proper size and remove the oil from children and pets.
  • Page 74 Tighten the filter 2 turns or to specified torque. Use a genuine SUZUKI oil filter 8. Mark the top dead center posi- or an equivalent filter designed tion on the “cap type” filter for your motorcycle.
  • Page 75: Engine Idle Speed Inspection

    NOTE: If the engine idle speed is NOTE: About 3000 ml (3.2 US qt) not within the specified range, ask of oil will be required when chang- your Suzuki dealer or a qualified ing oil only. mechanic to inspect and repair the motorcycle.
  • Page 76: Throttle Cable Adjustment

    THROTTLE CABLE FUEL HOSE ADJUSTMENT Fuel Tank Lift 1. Place the motorcycle on the side stand. Remove the seat by referring to the BATTERY section. 2. Remove the bolt 1. 2.0 – 4.0 mm (0.08 – 0.16 in) To adjust the cable play: 1.
  • Page 77 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 78: 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 79: 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 80: Final Gear Oil

    FINAL GEAR OIL Change the gear oil as follows: 1. Place the motorcycle on the side stand. 3. Remove the filler cap and add properly mixed coolant through the filler hole.  WARNING 2. Remove the oil filler cap 1. 3.
  • Page 81: Brakes

    BRAKES  WARNING This motorcycle has front disk and rear drum brakes. Operating the motorcycle with too little final gear oil can  WARNING cause the final drive unit to lock up and cause an accident. Failure to inspect and properly maintain the brakes increases Check for leaks and the correct your chance of having an acci-...
  • Page 82 Use only DOT4 brake fluid from a sealed container. Never use or mix dif- ferent types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a SUZUKI dealer or a qualified mechanic for inspection. 7-26...
  • Page 83 Inspect brake pad wear before each use. Ask your SUZUKI dealer or a qualified mechanic to replace brake pads if any pad is worn to the limit.
  • Page 84 Rear Brake Pedal Adjustment 20 – 30 mm (0.8 – 1.2 in) The rear brake pedal position and the free travel must be properly adjusted. Adjust the brake pedal in the following manner: 95 – 105 mm (3.7 – 4.1 in) 4.
  • Page 85 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 86: Tires

    TIRES  WARNING  WARNING Failure to perform break-in of the tires could cause tire slip Failure to follow these warn- and loss of control. ings may result in an accident due to tire failure. The tires on Use extra care when riding on your motorcycle form the cru- new tires.
  • Page 87 VL800 Tire Condition and Type Tire condition and tire type affect LOAD DUAL RIDING motorcycle performance. Cuts or SOLO RIDING OR SOLO WITH LIGHT cracks in the tires can lead to tire RIDING OR LITTLE WITH HEAVY failure and loss of motorcycle con-...
  • Page 88 If you use a different size or type of tire, motorcycle han- dling may be adversely affected, possibly resulting in loss of motor- cycle control. VL800 FRONT REAR NOTE: The “Triangle mark” indi- 130/90-16M/C 170/80-15M/C...
  • Page 89 Tubeless tires require different ser- vice procedures than tube tires. • Ask your SUZUKI dealer or a qualified mechanic to per- form tire repair, replacement, • Tubeless tires require an air-tight...
  • Page 90: 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. 7-34...
  • Page 91: Front Wheel Removal

    2. Remove the cap. Loosen the axle holder bolt 1. Loosen the axle 2 temporarily. NOTE: A special tool is necessary to loosen the axle. The special tool is available from a Suzuki dealer. 5. Remove speedometer 3. Place an accessory service gear box 3.
  • Page 92 Torque bolts and nuts to the proper specifications. If you are not sure of the proper pro- 6. Slide the front wheel forward. cedure, have your authorized SUZUKI dealer or a qualified NOTE: Never squeeze the front mechanic do this. brake lever...
  • Page 93: Rear Wheel Removal

    REAR WHEEL REMOVAL  WARNING Removing the rear wheel with- out use of an accessory stand can result in your motorcycle falling over and being dam- aged. 2. Disconnect coupler. Do not attempt road side Remove the bolts 1, 2. removal of the rear wheel.
  • Page 94 6. Draw out the axle 8. Rear torque link nut tightening torque: 25 N·m (2.5 kgf-m, 18.0 lbf-ft) NOTE: Apply a drop of SUZUKI THREAD LOCK “1322” to the rear frame mounting bolt 1, 2. Rear frame mounting bolt tightening torque: 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
  • Page 95: Light Bulb Replacement

    LIGHT BULB REPLACEMENT Headlight The wattage rating of each bulb is shown in the following chart. When replacing a burned out bulb, always use the same watt- age rating. CAUTION Using a light bulb with the wrong wattage rating can cause electrical system dam- age or shorten bulb life.
  • Page 96 Headlight Beam Adjustment The headlight beam can be adjusted both right and left or up and down if necessary. 3. Unhook bulb holder spring 4, and pull out the bulb 5. CAUTION To adjust the beam right and left: Oil from your skin may damage Turn the adjuster 1 clockwise or the headlight bulb or shorten counterclockwise.
  • Page 97 Turn Signal Light License Plate Light To replace the license plate light bulb, follow the procedure below: 1. Remove the screw 1. 2. Turn the lens counterclockwise and remove it. 1. Turn the license plate lens counterclockwise and remove 3. Push in on the bulb 2, turn it to the left, and pull it out.
  • Page 98: Fuses

    FUSES FUSES MAIN FUSE The fuses are located behind the left crank case cover. To access the fuses, remove the left crank The main fuse is located under case cover referring the front seat. To access the fuse, ENGINE COOLANT section. remove the seat by referring to the BATTERY section.
  • Page 99 If the new fuse *oxygen sensor, sole- blows in a short time, consult noids, ECU, fuel pump relay, your SUZUKI dealer or a quali- fan motor relay, starter relay, fied mechanic immediately. ignition coils, *canister purge solenoid, headlight relay and side stand relay.
  • Page 101: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..................8-2 IGNITION SYSTEM CHECK ................8-3...
  • Page 102: Troubleshooting

    CAUTION ble in the fuel injection system, Failure to troubleshoot a prob- take your machine to an autho- rized Suzuki dealer. Refer to the lem correctly can damage your “INSTRUMENT PANEL” section motorcycle. Improper repairs for an explanation of the fuel or adjustments may damage injection system indicator.
  • Page 103 If there is no spark, take Refer to the “INSTRUMENT your machine to your autho- PANEL” section for an explana- rized Suzuki dealer or a quali- tion of the fuel injection system fied mechanic. indicator. 3. Check the ignition system for intermittent spark.
  • Page 105: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................9-2 PROCEDURE FOR RETURNING TO SERVICE ..........9-3 CORROSION PREVENTION ................9-4 MOTORCYCLE CLEANING ................9-5 INSPECTION AFTER CLEANING ............... 9-6...
  • Page 106: Storage Procedure

    For this rea- son, Suzuki recommends that you ENGINE trust this maintenance work to 1. Pour one tablespoon of motor your authorized Suzuki dealer. If oil into each spark plug hole.
  • Page 107: Procedure For Returning To Service

    TIRES PROCEDURE FOR RETURNING Inflate the tires to the normal TO SERVICE specifications. 1. Clean the entire motorcycle. 2. Remove the oily rags from the EXTERNAL air cleaner intake and muffler • Spray all vinyl and rubber outlet. parts with rubber preservative. 3.
  • Page 108: Corrosion Prevention

    If the chips or scratches have gone through to the bare metal, have a Suzuki dealer make the repair. • Store your motorcycle in a dry, well-ventilated area. If you...
  • Page 109: Motorcycle Cleaning

    2. Wash the entire motorcycle surface. Your Suzuki with mild detergent or car dealer can help you select the wash soap using a sponge or right cover for your motorcycle. soft cloth. The sponge or cloth should be frequently soaked in the soap solution.
  • Page 110: Inspection After Cleaning

    Waxing the Motorcycle CAUTION After washing the motorcycle, waxing is recommended to further High pressure washers and protect and beautify the paint. parts cleaner can damage your Observe the precautions speci- motorcycle. fied by the wax manufacturer. Do not use high pressure INSPECTION AFTER CLEANING washers to clean your motorcy- cle.
  • Page 111: Consumer Information

    CONSUMER INFORMATION EMISSION CONTROL WARRANTY ..............10-2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-2 SERIAL NUMBER LOCATION ................10-3 REPORTING SAFETY DEFECTS ..............10-4 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....10-5 LOCATION OF LABELS ................... 10-6 10-1...
  • Page 112: Emission Control Warranty

    Federal law prohibits the following acts or the causing thereof; (1) WARRANTY the removal or rendering inopera- Suzuki Motor Corporation war- tive by any person other than for rants to the ultimate purchaser purposes of maintenance, repair, and each subsequent purchaser...
  • Page 113: Serial Number Location

    Whenever replacing parts on your motorcycle, Suzuki recommends that you use genuine Suzuki replacement parts or their equiva- The frame number 1 is stamped lent. on the steering head as shown in the illustration. The engine serial number 2 is stamped on the crankcase assembly.
  • Page 114: Reporting Safety Defects

    REPORTING SAFETY DEFECTS To contact American Suzuki, own- ers in the continental United If you believe that your vehicle States can call toll-free 1-800- has a defect which could cause a 444-5077, or write to: American crash or could cause injury or...
  • Page 115: 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 116: 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. 10-6...
  • Page 117 3 (VL800) WARNING DUAL RIDING SOLO RIDING COLD TIRE PRESSURE kgf/cm kgf/cm • Check tire condition, FRONT 2.00 2.00 wear, and cold tire REAR 2.50 2.50 pressure before each ride. • Replace only with tires FRONT REAR of listed size and type.
  • Page 118: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2510 mm (98.8 in) Overall width............ 970 mm (38.2 in) Overall height ..........1105 mm (43.5 in) Wheelbase ............1655 mm (65.2 in) Ground clearance..........140 mm (5.5 in) Seat height ............700 mm (27.6 in) Curb mass ............
  • Page 119 ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK DPR7EA-9 or DENSO X22EPR-U9 NGK DR7EA or DENSO X22ESR-U ... For 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 Front turn signal light........12V 21/5W Rear turn signal light ........12V 21W Speedometer light ...........LED Neutral indicator light........LED...
  • Page 120 INDEX ACCESSORIES AND EMISSION CONTROL LOADING....... 1-5 WARRANTY ......10-2 ACCESSORY INSTALLATION ENGINE COOLANT .....7-23 GUIDELINE ......6-2 ENGINE COOLANT ACCESSORY USE ....6-2 SOLUTION ......2-5 AIR CLEANER ....... 7-7 ENGINE IDLE SPEED INSPECTION......7-19 ENGINE OIL ....2-3 7-15 BATTERY....... 7-6 BE EXTRA SAFETY- CONSCIOUS ON BAD FINAL GEAR OIL ....7-24...
  • Page 121 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 ......9-5...
  • Page 122 REAR BRAKE PEDAL ..3-18 TAMPERING WITH NOISE REAR WHEEL CONTROL SYSTEM REMOVAL......7-37 PROHIBITED......10-2 REPORTING SAFETY THROTTLE CABLE DEFECTS......10-4 ADJUSTMENT .....7-20 RIDING ON HILLS ....5-5 TIRES ........7-30 RIGHT HANDLEBAR ... 3-15 TOOLS ........7-5 SERIAL NUMBER USING THE LOCATION ......
  • Page 123 WARNING Failure to follow these safety precautions may increase your risk of injury: Wear a helmet, eye protec- tion, and bright protective clothing. Don’t ride after consuming alcohol or other drugs. Slow down on slippery sur- faces, unfamiliar terrain, or when visibility is reduced.

This manual is also suitable for:

Vl800cVl800t2008 vl8002008 vl800t2008 vl800c

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  • #unknown Jul 02, 2018 07:43:
    I have a 2003 Volusia but lost my keys. So called local dealer he wanted 350$ plus tow...beca​use I lost my keys I bought slugs and want to get new keys cut. Having issue with the screws holding in the ignition, not sure if what kinda head a Philips, star, etc. is there a tool made for this?