Related Manuals for Suzuki VZR1800
Summary of Contents for Suzuki VZR1800
- Page 1 SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH: VZR1800 SERVICE MANUAL (99500-39293-01E) 9 9 5 0 1 - 3 9 5 9 0 - 0 1 E...
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Page 2: Table Of Contents
This manual describes service specifications, service data and servicing procedures which dif- fer from those of the VZR1800/NK9 (’09-model). NOTE: Please refer to the VZR1800/NK9 (’09-model) service manual for details which are not given in this manual. CONTENTS INFORMATION LABELS.................. - Page 3 2 VZR1800/ZL0 (’10-MODEL) VZR1800/ZL0 (’10-MODEL) CONTENTS HEADLIGHT HOUSING/TACHOMETER AND HEADLIGHT COVER BRACE..29 REMOVAL....................... 29 INSTALLATION ....................30 BATTERY GROUND WIRE ..................31 INSTALLATION ....................31 TIGHTENING TORQUE.................... 32 ENGINE......................32 DRIVELINE/AXLE................... 32 CHASSIS......................32 SERVICE DATA......................32 WIRING DIAGRAM....................35 WIRING HARNESS ROUTING.................
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Page 4: Information Labels
VZR1800/ZL0 (’10-MODEL) 3 INFORMATION LABELS VZR1800 VZR1800UF 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33, 51) 3 Vacuum hose routing label A (For E-33) 4 Fuel information label 5 Manual notice label... -
Page 5: Specifications
4 VZR1800/ZL0 (’10-MODEL) SPECIFICATIONS NOTE: Any differences between the VZR1800/NK9 (’09-model) and VZR1800/ZL0 (’10-model) in specifications are indicated with an asterisk mark (*). DIMENSIONS AND CURB MASS Overall length............* 2 450 mm (96.5 in) ..E-03, 28, 33 2 480 mm (97.6 in) ..Others Overall width ............ -
Page 6: Lubrication Points
VZR1800/ZL0 (’10-MODEL) 5 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. Throttle cable Brake lever holder Pillion footrest pivot Front footrest pivot Brake pedal pivot... -
Page 7: Engine Components Inspection And Servicing
6 VZR1800/ZL0 (’10-MODEL) ENGINE COMPONENTS INSPECTION AND SERVICING CAMSHAFT Each exhaust camshaft I.D. code A has been changed which is stamped on the camshaft end. Front cylinder Rear cylinder I.D. code A Front cylinder Rear cylinder CAM WEAR Cam height H Service Limit (EX.): 40.18 mm (1.582 in) -
Page 8: Clutch
VZR1800/ZL0 (’10-MODEL) 7 CLUTCH CONSTRUCTION DRIVE PLATE: Drive plate No. 1 ...6 pcs. Drive plate No. 2 ..Any 1 pc. Drive plate No. 3 Drive plate No. 4 Spring washer Spring washer seat DRIVEN PLATE: Driven plate No. 1 ...5 pcs. - Page 9 8 VZR1800/ZL0 (’10-MODEL) INSPECTION CLUTCH PLATE THICKNESS NOTE: Wipe off engine oil from the clutch plates with a clean rag. • Measure the thickness of drive and driven plates with a ver- nier calipers. If each plate is not within the service limit or standard range, replace it with a new one.
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Page 10: Crankshaft Journal Bearing
VZR1800/ZL0 (’10-MODEL) 9 CRANKSHAFT JOURNAL BEARING SELECTION Crankshaft journal oil clearance: Standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in) Service Limit: 0.080 mm (0.0031 in) 09900-22301: Plastigauge (0.025 – 0.076 mm) Bearing thickness specification Color code Color (Part No.) -
Page 11: Driveline/Axle
10 VZR1800/ZL0 (’10-MODEL) DRIVELINE/AXLE SECONDARY GEAR SHIMS ADJUSTMENT 55 N . m (5.5 kgf-m, 40.0 lbf-ft) Adjust backlash and tooth contact by selecting shims. (Use two pieces of shims.) Shim 1 size table Part number Thickness 24945-48G10-030 0.30 mm (0.012 in) 24945-48G10-035 0.35 mm (0.014 in) -
Page 12: Fi System
VZR1800/ZL0 (’10-MODEL) 11 FI SYSTEM FI SYSTEM PARTS LOCATION A Tachometer/gear position B ISC valve (ISCV) C Intake air pressure sensor #2 (IAPS) D Ignition coil #1 (IG COIL) E Secondary throttle position sensor (STPS) F Throttle position sensor (TPS) - Page 13 12 VZR1800/ZL0 (’10-MODEL) A Speedometer B Intake air temperature sensor (IATS) C PAIR control solenoid valve D Fuel injector #1 E Fuel injector #2 F Intake air pressure sensor #1 (IAPS) G Fuel pump H Ignition coil/plug cap #1 I Tip-over sensor (TOS)
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Page 14: Exhaust System
VZR1800/ZL0 (’10-MODEL) 13 EXHAUST SYSTEM CONSTRUCTION 23 N·m (2.3 kgf-m, 16.5 lbf-ft) Apply anti-seize 23 N·m compound to thread part. (2.3 kgf-m, 16.5 lbf-ft) Muffler (#1) Muffler (#2) 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 28 N·m... -
Page 15: Front Fork
14 VZR1800/ZL0 (’10-MODEL) FRONT FORK CONSTRUCTION 1 O-ring 6 Oil seal stopper ring A Front fork cap bolt 2 Spacer 7 Dust seal B Inner rod lock nut 3 Outer tube 8 Spring C Damper rod bolt 4 Oil seal retainer... -
Page 16: Removal And Disassembly
VZR1800/ZL0 (’10-MODEL) 15 REMOVAL AND DISASSEMBLY • Remove the headlight housing assembly. ( Page 29) • Remove the front wheel. ( VZR1800K6 9-9) • Remove the front reflex refractor 1. (For E-03, 28, 33) • Remove the bolts, left and right and front fender 2. - Page 17 16 VZR1800/ZL0 (’10-MODEL) • Remove the front fork cap bolt 4 from the inner rod by loos- ening the lock nut. • Remove the special tools. After removing the front fork cap bolt 4, avoid hold- ing the outer tube vertically by hand to prevent the inner tube from falling and damaged.
- Page 18 VZR1800/ZL0 (’10-MODEL) 17 • Remove the inner rod/damper rod (cartridge) 8. Do not disassemble the inner rod/damper rod (car- tridge). • Extract the outer tube from the inner tube. NOTE: Be careful not to damage the “ANTI-FRICTION” metals. • Remove the dust seal 9 and oil seal stopper ring 0.
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Page 19: Inspection
18 VZR1800/ZL0 (’10-MODEL) INSPECTION INNER AND OUTER TUBES • Inspect the inner tube outer surface and outer tube inner sur- face for scratches. • Inspect the “ANTI-FRICTION” metal surfaces for scratches. • If any defects are found, replace them with a new one. -
Page 20: Reassembly
VZR1800/ZL0 (’10-MODEL) 19 REASSEMBLY Reassemble the front fork in the reverse order of disassembly. Pay attention to the following points: OIL SEAL AND DUST SEAL • Install the dust seal, oil seal stopper ring, oil seal and oil seal retainer onto the inner tube. - Page 21 • Compress it fully. • Pour specified front fork oil up to the top level of the outer tube. 99000-99044-L01: SUZUKI FORK OIL L01 or an equivalent fork oil • Move the inner rod slowly with the special tool ten times and more until no more bubbles come out from the oil.
- Page 22 VZR1800/ZL0 (’10-MODEL) 21 FRONT FORK INNER ROD LOCK NUT • Tighten the lock nut 1 to the bottom of inner rod threads. FORK SPRING • Install the fork spring as shown in the illustration. Upper side Lower side • Install the spring 1 and spacer 2.
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Page 23: Installation
22 VZR1800/ZL0 (’10-MODEL) INSTALLATION Install the front fork in the reverse order of removal. Pay atten- tion to the following points: • Install the front fork to the steering stem and steering stem upper bracket. • Install the top of outer tube 5 mm (0.2 in) A higher than the upper surface of the steering stem upper bracket and tighten the front fork lower clamp bolts 1 to the specified torque. -
Page 24: Steering
VZR1800/ZL0 (’10-MODEL) 23 STEERING CONSTRUCTION 1 Handlebar clamp 6 Steering stem upper bearing C Front fork upper clamp bolt 2 Handlebar clamp holder 7 Steering stem lower bearing D Handlebar holder bolt 3 Steering stem upper bracket 8 Steering stem... -
Page 25: Rear Brake Caliper And Bracket
24 VZR1800/ZL0 (’10-MODEL) REAR BRAKE CALIPER AND BRACKET INSTALLATION • Apply THREAD LOCK SUPER to the brake caliper bracket mounting bolt 1 and tighten its to the specified torque. • Apply THREAD LOCK SUPER to the rear brake caliper mounting bolts 2 and tighten them to the specified torque. -
Page 26: Speedometer And Tachometer
VZR1800/ZL0 (’10-MODEL) 25 SPEEDOMETER AND TACHOMETER DESCRIPTION This speedometer and tachometer mainly consists of the stepping motor (except for tachometer), LCD (Liq- uid Crystal Display) and LED (Light Emitting Diode). The speedometer pointer is driven by the stepping motor. The LCDs indicate Tachometer, Gear position/Engine coolant temperature/Oil pressure temperature, Odo/ Trip1/Trip2/FI (DTC) and Clock/Fuel level respectively. -
Page 27: Tachometer Removal And Disassembly
26 VZR1800/ZL0 (’10-MODEL) TACHOMETER REMOVAL AND DISASSEMBLY • Remove the headlight housing assembly. ( Page 30) • Remove the headlight upper cover. ( Page 30) • Remove the tachometer 1. • Disassemble the tachometer as follows. ☆ : Hooked part Do not attempt to disassemble the tachometer unit 2. - Page 28 VZR1800/ZL0 (’10-MODEL) 27 ENGINE COOLANT TEMPERATURE METER AND INDICATOR INSPECTION ECT sensor inspection ( VZR1800K6 8-9) • Remove the right frame side cover. ( VZR1800K6 9-5) • Remove the right air cleaner box. ( VZR1800K6 6-13) • Disconnect the ECT sensor coupler 1.
- Page 29 28 VZR1800/ZL0 (’10-MODEL) FUEL LEVEL METER INSPECTION • Lift and support the fuel tank. ( VZR1800K6 6-3) • Disconnect the fuel pump lead wire coupler 1. • Connect variable resistor between the R/B and B/W lead wires at the wire harness.
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Page 30: Headlight Housing/Tachometer And Headlight Cover Brace
VZR1800/ZL0 (’10-MODEL) 29 HEADLIGHT HOUSING/TACHOME- TER AND HEADLIGHT COVER BRACE REMOVAL • Remove the bolts 1. ☆ : Hooked part • Disconnect the headlight coupler 2 and tachometer couplers 3. • Remove the headlight housing assembly 4. • Remove the headlight upper cover 5. -
Page 31: Installation
30 VZR1800/ZL0 (’10-MODEL) • Disconnect the front turn signal light couplers 0. • Remove the front turn signal lights B by removing the mounting screws A. • Remove the front turn signal light cover bolt C. • Remove the front turn signal cover E by removing the cover bolts D. -
Page 32: Battery Ground Wire
VZR1800/ZL0 (’10-MODEL) 31 BATTERY GROUND WIRE INSTALLATION The battery ground wire fixing point was changed. Clamp Battery ground wire Lower crankcase... -
Page 33: Tightening Torque
Front turn signal light mounting screw 0.55 SERVICE DATA NOTE: Any differences between the VZR1800/NK9 (’09-model) and VZR1800/ZL0 (’10-model) in service data are indicated with an asterisk mark (*) and highlighting (halftone screen). CAMSHAFT + CYLINDER HEAD Unit: mm (in) - Page 34 VZR1800/ZL0 (’10-MODEL) 33 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure * 900 – 1 800 kPa 800 kPa (Automatic de-comp. actuated) (9.0 – 18.0 kgf/cm , 128 – 256 psi) (8.0 kgf/cm , 114 psi)
- Page 35 34 VZR1800/ZL0 (’10-MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 23.010 – 23.018 23.040 (0.9059 – 0.9062) (0.9071) Conrod big end side clearance 0.100 – 0.200 0.30 (0.0039 – 0.0078) (0.012) Conrod big end width 23.95 –...
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Page 36: Wiring Diagram
* 115 (without spring, inner tube fully — (4.5) compressed) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil — Front fork oil capacity (each leg) * 718 ml — (24.3/25.3 US/lmp oz) Rear shock absorber spring —... -
Page 37: Wiring Harness Routing
36 VZR1800/ZL0 (’10-MODEL) WIRING HARNESS ROUTING * 1 : Cut off the excess end of clamp. Wiring harness Face the lead wire Clamp to the lower. Clamp ISC valve Set the speedometer harness to the right side. Wiring harness Clamp... - Page 38 VZR1800/ZL0 (’10-MODEL) 37 * 2 : Cut off the excess end of clamp. Clamp Clamp Face the clamp locking part downward. Handlebar switch (L & R) Handlebar switch (R) Do not slack the handlebar switch lead wire. 0 – 10 mm Front brake hose (0.0 –...
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Page 39: Cable Routing
38 VZR1800/ZL0 (’10-MODEL) CABLE ROUTING Pass the throttle cables behind the right handlebar switch lead wire, brake switch lead wire and brake hose. Throttle cable clip Headlight cover brace Throttle cable No.2 Throttle cable No.1 250 mm (9.8 in) Clutch cable Cable guide No.2... -
Page 40: Front Brake Hose Routing
VZR1800/ZL0 (’10-MODEL) 39 FRONT BRAKE HOSE ROUTING 1 Front brake hose Tighten the bolt after positioning the brake hose 2 Front brake caliper (R) joint to the stopper of headlight cover brace. 3 Front brake caliper (L) * 3 Fix the brake hose to the clamp. -
Page 41: Rear Brake Hose Routing
40 VZR1800/ZL0 (’10-MODEL) REAR BRAKE HOSE ROUTING * 10 * 10 30˚ 14˚ 28˚ 1 Stopper * 2 Clamp ends should face upward. Insert the reservoir hose fully to the reservoir tank and 2 Reservoir tank brake master cylinder. 3 Brake master cylinder * 4 Face the white paint on reservoir hose to forward. -
Page 42: Cooling System Hose Routing
VZR1800/ZL0 (’10-MODEL) 41 COOLING SYSTEM HOSE ROUTING : The ends of the clamp should face..: The clamp screw head should face..After the radiator conduction has contacted the frame lower flange, tighten the bolt. Radiator cap Keep clearance between clamp and hose. -
Page 43: Fuel Tank Installation
42 VZR1800/ZL0 (’10-MODEL) FUEL TANK INSTALLATION 11 N . m (1.1 kgf-m, 8.0 lbf-ft) Forward Outside 1 Heat shield 6 Fuel tank cushion 2 Fuel pump 7 Rear fender cover cushion 3 Clamp 8 Apply instant adhesive to the shaded portion. -
Page 44: Left Frame Covers Installation
VZR1800/ZL0 (’10-MODEL) 43 LEFT FRAME COVERS INSTALLATION 1 Rear fender 5 Lower side cover 2 Rear fender cover 6 Cushion ± ± 3 Rear side cover 7 10 2 mm (0.4 0.1 in) ± ± 4 Side cover 1 mm (0... -
Page 45: Right Frame Covers Installation
44 VZR1800/ZL0 (’10-MODEL) RIGHT FRAME COVERS INSTALLATION 1 Rear fender 5 Lower cover 2 Rear fender cover 6 Cushion ± ± 3 Rear side cover 7 15 2 mm (0.6 0.1 in) ± ± 4 Side cover 1 mm (0... -
Page 46: Headlight Cover Installation
VZR1800/ZL0 (’10-MODEL) 45 HEADLIGHT COVER INSTALLATION 1 Headlight lower cover 5 Headlight housing bracket cover * 1 To headlight 2 Headlight housing brace 6 Headlight cover brace * 2 To front cover 3 Headlight cover 7 Steering stem upper bracket... -
Page 47: Front Turn Signal Light Installation
46 VZR1800/ZL0 (’10-MODEL) FRONT TURN SIGNAL LIGHT INSTALLATION 1.5 N . m 0.15 kgf-m 1.0 lbf-ft 5.5 N . m 0.55 kgf-m 4.0 lbf-ft 5.5 N . m 0.55 kgf-m 4.0 lbf-ft 1 Front turn signal cover 8 Headlight housing bracket cover... -
Page 48: Secondary Gear Case Cover Damper Installation
VZR1800/ZL0 (’10-MODEL) 47 SECONDARY GEAR CASE COVER DAMPER INSTALLATION 1 Secondary gear case cover 4 Secondary gear case cover damper 2 Engine oil note 5 5 – 10 mm (0.2 – 0.4 in) 3 Secondary gear case cover damper 6 5 – 7 mm (0.2 – 0.3 in) - Page 49 Prepared by January, 2010 Part No. 99501-39590-01E Printed in Japan...
- Page 50 Printed in Japan...