Suzuki VL800 Motorcycle User Manual

Suzuki VL800 Motorcycle

GENERAL PRECAUTIONS

WARNINGS

• Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.
• When two or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
• When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled.
• After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines and fittings related to the system for leaks.

CAUTION

• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.
• Be sure to use special tools when instructed.
• Make sure that all parts used in reassembly are clean. Lubricate them when specified.
• Use the specified lubricants, bonds, or sealants.
• When removing the battery, disconnect the – battery lead wire first and then the + battery lead wire.
• When reconnecting the battery, connect the + battery lead wire first, then the – battery lead wire. Finally, cover the + battery terminal with the terminal cover.
• When performing service on electrical parts, disconnect the – battery lead wire, unless the service procedure requires the battery power.
• When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first. Always tighten the nuts and bolts from the inside, working out diagonally, and to the specified torque.
• Whenever you remove oil seals, gaskets, packing, O rings, self-locking nuts, locking washers, cotter pins, circlips, and other specified parts, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any leftover material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure it is completely seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
• After reassembling, check parts for tightness and proper operation.

SUZUKI VL800K1 (2001-MODEL)

* The difference between a photograph and the actual motorcycle depends on the markets.

SERIAL NUMBER LOCATION

The frame serial number or VIN (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

FUEL, OIL, AND ENGINE COOLANT RECOMMENDATION

FUEL (For USA and CANADA)

1. Use only unleaded gasoline of at least 87 pump octane (R+M/2 ) method or 91 octane or higher rated by the Research Method.
2. Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible.
3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.
5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline.
6. Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

FUEL (For the other countries)
Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

ENGINE OIL (For USA)

SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil that is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not available, select an alternative according to the right chart.

ENGINE OIL (For the other countries)

Use a premium quality 4-stroke motor oil to ensure the longer service life of your motorcycle. Use only oils that are rated SF or SG under the API service classification. The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.

GEAR OIL (FINAL DRIVE GEAR OIL)

Use SAE 90 hypoid gear oil, which is rated GL-5 under API classification system. If you operate the motorcycle where ambient temperature is below 0°C (32°F), use SAE 80 hypoid gear oil.

FRONT FORK OIL

Use SUZUKI FORK OIL SS-08 (#10) or an equivalent fork oil.

ENGINE COOLANT

Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing antifreeze, even if the atmospheric temperature does not go below the freezing point. Use an antifreeze designed for aluminum radiators. Suzuki recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators. Mix only distilled water with the antifreeze. Other types of water can corrode and clog the aluminum radiator. Mix distilled water and antifreeze at a ratio of 50 : 50 – 40 : 60.
For more information, refer to the cooling system section.

BREAK-IN PROCEDURES

During manufacturing, only the best possible materials are used, and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depend on the care and restraint exercised during its early life. Refer to the following break-in engine speed recommendations.

• Keep to these break-in throttle positions during the break-in period.
  Break-in throttle operation
  Initial 800 km ( 500 miles): Less than ½ throttle
  Up to 1,600 km (1,000 miles): Less than ¾ throttle
• Upon reaching an odometer reading of 1,600 km (1,000 miles), you can subject the motorcycle to full throttle operation.

CYLINDER IDENTIFICATION

The engine cylinders are identified as #1 and #2, as counted from rear to front (as viewed by the rider on the seat).

INFORMATION LABELS

SPECIFICATIONS

DIMENSIONS AND DRY MASS

• Overall length ………………………………………………………. 2 510 mm (98.818 in)
• Overall width ……………………………………………………….. 985 mm (38.779 in)
• Overall height ………………………………………………………. 1 110 mm (43.700 in)
• Wheelbase ………………………………………………………….. 1 650 mm (64.960 in)
• Ground clearnce ………………………………………………….. 140 mm ( 5.511 in)
• Seat height ………………………………………………………….. 700 mm (27.559 in)
• Dry mass…………………………………………………………….. 239 kg (53.727 lbs)

ENGINE

• Type……………………………………………………………………. Four-stroke, Liquid-cooled, OHC
• Number of cylinders ……………………………………………… 2
• Bore …………………………………………………………………… 83 mm (3.268 in)
• Stroke …………………………………………………………………. 74.4 mm (2.929 in)
• Displacement ………………………………………………………. 805 cm3 (49.1 cu in)
• Compression ratio ………………………………………………… 9.4 : 1
• Carburetor …………………………………………………………… BDSR34
• Air cleaner …………………………………………………………… Non-woven fabric element
• Starter system……………………………………………………… Electric
• Lubrication system ……………………………………………….. Wet sump
• Idle speed …………………………………………………………… 1 100 ± 100 r/min

TRANSMISSION

• Clutch …………………………………………………………….. Wet multi-plate type
• Transmission ……………………………………………… .. 5-speed, constant mesh
• Gearshift pattern ……………………………………….. …. … 1-down, 4-up
• Primary reduction ratio ……………………….. ………… ….. 1.690 (71/42)
• Secondary reduction ratio …………………. …… ………… 1.133 (17/15)
• Final reduction ratio ……………………… .. ………… 3.090 (34/11)
• Gear ratios, Low …………………………. …. ……………… 2.461 (32/13)
  • 2nd……………………. ……… ………………… 1.631 (31/19)
  • 3rd ……………….. . ……. …………………… 1.227 (27/22)
  • 4th…………………….. …. ……………………… 1.000 (25/25)
  • Top ……………….. … …………………………. 0.814 (22/27)
• Drive system ……………….. …… ……………………………. Shaft drive

CHASSIS

• Front suspension …………………………………………………. Telescopic, coil spring, oil damped
• Rear suspension ……………………………………………….. Link type, coil spring, oil damped, spring pre-load 7-way adjustable
• Steering angle …………………………………………………….. 38° (right & left)
• Caster ………………………………………………………………… 33° 20’
• Trail …………………………………………………………………….. 141 mm (3.55 in)
• Turning radius ……………………………………………………… 3.0 m (9.8 ft)
• Front brake ………………………………………………………….. Disc brake
• Rear brake ………………………………………………………….. Drum brake
• Front tire size ………………………………………………………. 130/90-16 67H, tube or 30/90-16M/C 67H, tube
• Rear tire size ……………………………………………………….. 170/80-15M/C 77H, tube
• Front fork stroke …………………………………………………… 140 mm (5.5 in)
• Rear wheel travel …………………………………………………. 105 mm (4.1 in)

ELECTRICAL

• Ignition type ………………………………………………………… Electronic ignition (Transistorized)
• Ignition timing ………………………………………………………. 5° B TD.C at 1 110 r/min
• Spark plug …………………………………………………………… NGK: DPR8EA-9 or DENSO: X24EPR-U9
• Battery ……………………………………………………………….. 12 V 36 kC (10 Ah)/10HR
• Generator …………………………………………………………… Three-phase A.C. Generator
• Main fuse ……………………………………………………….. 30 A
• Fuse ……………………………………………………………. …. 15/15/10/10/10/10 A
• Headlight ………………………………………………….. …….. 12 V 60/55 W
• Position/parking light ………………………………………. ….. 12 V 4 W……..Except for E-03, 24, 28, 33
• Front turn signal light ………………………………… ………. 12 V 21 W………. E-02, 19, 24 12 V 21/5 W……. E-03, 28, 33
• Rear turn signal light …………………………… …. ………… 12 V 21 W
• Brake light/Taillight ……………………… …………………….. 12 V 21/5 W
• Speedometer light……………………. ……… ……………….. LED
• Neutral indicator light …………….. . ………………………… LED
• High beam indicator light ……….. …. ……………………… LED
• Turn signal indicator light …. ……. …………………………. LED
• Oil pressure light…………………………………………………… LED

CAPACITIES

• Fuel tank ……… …… ………………………………………. 17.0 L (4.5/3.7 US/lmp gal)
• Engine oil, oil change …………………………………………… 3,000 ml (3.2/2.6 US/lmp qt)
• with filter change ………………………………….. 3 400 ml (3.6/3.0 US/lmp qt)
• overhaul ……………………………………………… 3 700 ml (3.9/3.3 US/lmp qt)
• Final gear oil ……………………………………………………….. 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/lmp qt)
• Engine coolant …………………………………………………….. 1,500 ml (1.5/1.3 US/lmp qt)
• Front fork oil (each leg) …………………………………………. 412 ml (13.9/14.5 US/imp oz)
  These specifications are subject to change without notice.

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, whichever comes first.

IMPORTANT (USA only):
The periodic maintenance intervals and service requirements have been established by EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards, and it will also ensure the reliability and performance of the motorcycle. The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, mile,s and time for your convenience.

NOTES:
More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

I = Inspect and adjust, clean, lubricate or replace as necessary.
R = Replace
T = Tighten

LUBRICATION POINTS

Proper lubrication is important for smooth operation and the long life of each working part of the motorcycle. Major lubrication points are indicated below.

NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts that are subject to rust with a rust preventative spray, especially whenever the motorcycle has been operated under wet or rainy conditions.

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.

AIR CLEANER

• Remove the screws and air cleaner case cover.
• Remove the air cleaner element.
• Carefully use air hose to blow the dust from the cleaner element.

NOTE:
Always apply air pressure on the engine side of the air cleaner element. If air pressure is applied improperly, dirt will be forced into the pores of the air cleaner element, thus restricting air flow through the air cleaner element.

• Reinstall the cleaned or new air cleaner element in the reverse order of removal.

NOTE:
If driving under dusty conditions, clean the air cleaner element more frequently. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component.

• Remove the drain plugs from the air cleaner box to allow any water to drain out.
• Remove the spark plug caps.
• Remove the spark plugs with a spark plug wrench.

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions.

ENGINE CENTER

ENGINE LEFT SIDE ENGINE RIGHT SIDE

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure.

• Drain engine oil.
• Drain engine coolant.
• Remove the seats.
• Remove the fuel tank.
• Disconnect the battery – lead wire.
• Remove the frame head covers 1.
• Remove the radiator.
• Remove the left frame cover and the secondary gear case cover.
• Remove the engine coolant reservoir tank.

RADIATOR AND WATER HOSE

COOLING CIRCUIT INSPECTION

Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness.

• Remove the fuel tank. (#5-3)
• Remove the radiator cap 1 and connect the tester to the filler.

WARNING
Do not remove the radiator cap when the engine is hot.

• Give a pressure of about 120 kPa (1.2 kgf/cm2, 17 psi) and see if the system holds this pressure for 10 seconds.
• If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part.

WARNING
When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant.
CAUTION
Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged.

RADIATOR REMOVAL

• Remove the fuel tank. (#5-3)
• Remove the frame head covers 1.
• Disconnect the water hoses.
• Drain engine coolant.
• Remove the radiator cover 2.
• Remove the radiator mounting bolts.
• Remove the radiator.

CHASSIS

FRONT BRAKE

CONSTRUCTION

1. Cap
2. Diaphragm
3. Master cylinder
4. Piston set
5. Brake hose
6. Caliper holder
7. Caliper
8. Pad set
9. Piston
10. Piston and dust seal
11. Insulator

• A Master cylinder mounting bolt
• B Brake hose union bolT
• C Brake caliper mounting bolt

WARNINGS

• The brake system is filled with a glycol-based brake fluid, which is classified DOT 4. Do not use or mix other types of brake fluid, such as silicone-based and petroleum-based brake fluids when refilling the brake system, otherwise serious damage to the brake system will result.
• Do not use any brake fluid taken from old, used, or unsealed containers.
• Do not reuse brake fluid left over from the last servicing or that has been stored for a long period of time.
• When storing brake fluid, be sure to seal the container completely and keep it out of the reach of children.
• When replenishing brake fluid, be sure not to get any dust or other foreign materials in the fluid.
• When washing brake components, always use new brake fluid. Do not use cleaning solvent.
• A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads and clean the brake disc with high-quality brake cleaner or a neutral detergent.

BRAKE PAD REPLACEMENT

• Remove the guide hook A.
• Remove the brake caliper by removing the brake caliper mounting bolts.
• Remove the pin 1.
• Remove the pad pin 2.
• Remove the brake pads 3.

CAUTION
* Do not operate the brake lever during or after brake pad removal.
* Replace the brake pads as a set; otherwise, braking performance will be adversely affected.

• Install the new brake pads.
• Tighten the brake caliper mounting bolts to the specified torque.

Brake caliper mounting bolts: 39 N.m (3.9 kgf · m, 28 lb-ft)

• Install the guide hook A.
  NOTE:
  After replacing the brake pads, pump the brake lever a few times to check for proper brake operation and then check the brake fluid level.

BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handlebars straight
•  Remove the master cylinder reservoir cap and diaphragm.
• Remove as much old brake fluid as possible.
• Fill the reservoir with new brake fluid.
  * Specification and classification: DOT 4
• Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system.
• Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.

CAUTION: Bleed air from the brake system.

BRAKE CALIPER REMOVAL AND DISASSEMBLY

• Remove the guide hook A
• Disconnect the brake hose from the brake caliper by removing the brake hose union bol 1 and allow the brake fluid to drain into a suitable receptacle.
• Remove the brake caliper by removing the brake caliper mounting bolts 2.

WARNINGS

• Do not reuse the brake fluid left over from the last servicing or which has been stored for a long period of time, otherwise serious damage to the brake system will result.
• Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and oil leakage.

• Remove the brake pads.
• Remove the insulator.
• Remove the brake caliper holder.
• Remove the spring.
• Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using compressed air.

WARNING
Do not use extremely high pressure to remove the brake caliper pistons, otherwise damage to the pistons will result.

• Remove the dust seals and piston seals.

WARNING
Do not reuse the dust seals and piston seals to prevent fluid leakage.ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

CONNECTORS

• When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
• When connecting a connector, push it in so it is firmly attached.
• Inspect the connector for corrosion, contamination, and any breakage in the cover.

COUPLERS

• With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a coupler, push it in until the lock clicks shut.
• When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires.
• Inspect each terminal on the coupler for looseness or bends.
• Inspect each terminal for corrosion and contamination.

CLAMPS

• Refer to the “WIRE HARNESS ROUTING” section for proper clamping procedures. (!9-13 and 9-14)
• Bend the clamp properly, as shown in the illustration.
• When clamping the wire harness, do not allow it to hang down.
• Do not use wire or any substitutes for the band-type clamp.

FUSES

• When a fuse blows, always investigate the cause, correct the problem, and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use any substitutes for he fuse (e.g., wire).

SEMICONDUCTOR EQUIPPED PARTS

• Do not drop any part that contains a semiconductor (e.g., ignitor unit, regulator/rectifier).
• When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.

BATTERY

• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).
• During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open area.
• Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.

CONNECTING THE BATTERY

• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the – battery lead wire first.
• When connecting the battery lead wires, be sure to connect the + battery lead wire first.
• If the terminal is corroded, remove the battery, pour warm water over it , and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the battery terminals.
• Install the cover over the + battery terminal.

WIRING PROCEDURE

• Properly route the wire harness according to the “WIRE ROUTING” section.

USING THE MULTICIRCUIT TESTER

• Properly use the multi-circuit tester + and – probes. Improper use can cause damage to the motorcycle and tester.
• If the voltage and current values are not known, begin measuring in the highest range
• When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF position.

LOCATION OF ELECTRICAL COMPONENTS

1. Ignition switch
2. Ignition coil #2
3. Fuel level gauge
4. Rear brake switch
5. Cooling fan
6. Cooling fan thermo-switch
7. Speedometer sensor
8. Ignition coil #1
9. Throttle position sensor
10. Starter relay/main fuse
11. Battery
12. Ignitor
13. Engine coolant temperature sensor
14. Horn
15. Starter motor
16. Oil pressure switch
17. Generator
18. Gear position switch
19. Side-stand switch
20. Fuse box
21. Turn signal side-stand relay
22. Regulator/rectifier

TROUBLESHOOTING

ENGINE

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Suzuki VL800 Motorcycle-FAQs