Suzuki Intruder VL800 Manuals

Manuals and User Guides for Suzuki Intruder VL800. We have 4 Suzuki Intruder VL800 manuals available for free PDF download: Service Manual, Supplementary Service Manual, Manual, Owner's Manual

Suzuki Intruder VL800 Service Manual (639 pages)

Brand: Suzuki | Category: Motorcycle | Size: 58.92 MB

Chassis

323
- How to Use this Manual
  4
- General Information
  7
- General Precautions
  8
- Serial Number Location
  10
- Brake Fluid
  11
- Engine Coolant
  11
- Front Fork Oil
  11
- Cylinder Identification
  12
- Information Labels
  13
- Dimensions and Dry Mass
  14
- Periodic Maintenance
  17
- Periodic Maintenance Chart
  18
- Lubrication Points
  19
- Air Cleaner
  20
- Spark Plug/Ignition Coil/Plug Cap Installation
  22
- Valve Clearance
  22
- Engine Oil and Oil Filter
  24
- Engine Idle Speed
  26
- Fuel Hose
  26
- Throttle Cable Play
  27
- Cooling System
  29
- Final Gear Oil
  31
- Tire Tread Depth
  34
- Exhaust Pipe Bolt and Nut
  35
- Front Fork
  35
- Chassis Bolts and Nuts
  36
- Compression Pressure Check
  38
- Oil Pressure Check
  39
- Engine Removal and Installation
  42
- Engine Installation
  47
- Engine Disassembly
  50
- Cylinder Head Cover
  61
- Engine Components Inspection and Servicing
  61
- Cylinder Head
  64
- Piston Diameter
  72
- Piston Ring End Gap
  73
- Piston Ring Groove Width
  73
- Piston Ring Thickness
  73
- Oil Pump
  84
- Oil Jet
  88
- Gearshift Fork
  88
- Engine Reassembly
  92
- Shaft Drive
  112
- Final Gear Case Installation
  134
- Fuel and Lubrication System
  135
- Fuel Pump
  136
- Diaphragm and Piston Operation
  144
- Slow System
  145
- Main System
  146
- Float System
  147
- Accelerator Pump System
  148
- Carburetor Cleaning
  154
- Carburetor Inspection
  154
- Reassembly and Reinstallation
  157
- Lubrication System Chart
  160
- Oil Pan
  160
- Cooling System
  163
- Cooling Circuit Inspection
  165
- Radiator Removal
  166
- Water Hose Inspection
  167
- Radiator Inspection and Cleaning
  167
- Radiator Remounting
  167
- Radiator Cap Inspection
  167
- Cooling Fan
  168
- Removal and Disassembly
  172
- Water Pump
  172
- Reassembly and Installation
  174
- Chassis
  177
- Exterior Parts
  178
- Brake Pad Replacement
  186
- Brake Fluid Replacement
  187
- Brake Caliper Inspection
  188
- Brake Caliper Reassembly and Remounting
  189
- Brake Disc Inspection
  190
- Master Cylinder Removal and Disassembly
  191
- Master Cylinder Inspection
  192
- Master Cylinder Reassembly and Remounting
  192
- Steering Tension Adjustment
  211
- Rear Wheel
  212
- Rear Brake
  218
- Rear Brake Rod
  220
- Reassembly Remounting
  221
- Electrical System
  233
- Cautions in Servicing
  234
- Connecting the Battery
  235
- Using the Multi Circuit Tester
  235
- Charging System
  238
- Troubleshooting
  238
- Starter Motor Removal and Disassembly
  243
- Starter Motor Inspection
  244
- Starter Motor Reassembly
  244
- Starter Relay Inspection
  245
- Starter Relay
  261
- Initial Charging
  263
- Recharging Operation
  265
- Servicing Information
  267
- Wire Harness Routing
  279
- Fuel Hose Routing
  283
- Battery Protector
  286
- Speed Sensor Lead Wire Routing
  286
- Secondary and Final
  291
- Emission Control Information
  303
- Evaporative Emission Control System Inspection
  306
- Vl800K2 ('02- Model)
  309
- Table of Contents
  323
- Brake Light/Taillight
  330
- Speedometer Light
  330
- Neutral Indicator Light
  330
- High Beam Indicator Light
  330
- Turn Signal Indicator Light
  330
Vl800K4 ('04-Model)

337
- Specifications
  338
- Service Data
  339
- Periodic Maintenance Chart
  347
- Cooling Hose Routing
  348
- Rear Combination Light Installation
  349
Vl800K5 ('05-Model)

353
- Vl800K5 ('05- Model)
  353
- Specifications
  354
- Abbreviations Used in this Manual
  355
- Sae-To-Former Suzuki Term
  357
- Service Data
  359
- Periodic Maintenance Chart
  369
- Precautions in Servicing
  370
  - Electrical Parts
    370
  - Electrical Circuit Inspection Procedure
    373
- Fi System Technical Features
  377
  - Injection Stop Control
    378
  - Fi System Parts Location
    379
  - Fi System Wiring Diagram
    381
  - User Mode
    382
- Self-Diagnosis Function
  382
  - Dealer Mode
    383
  - Tps Adjustment
    385
- Fail-Safe Function
  386
- Fi System Troubleshooting
  387
  - Visual Inspection
    388
  - Use of Sds Diagnostic Procedures
    390
  - Show Data When Trouble
    392
  - Displaying Data at the Time of Dtc
    392
- Ecm Terminal
  394
  - Malfunction Code and Defective Condition
    395
- Sensors
  442
  - Ckp Sensor Inspection
    442
  - Ckp Sensor Removal and Installation
    442
  - Iap Sensor Inspection
    442
  - Iap Sensor Removal and Installation
    442
  - Tp Sensor Inspection
    442
  - Tp Sensor Removal and Installation
    442
  - Ect Sensor Inspection
    442
  - Ect Sensor Removal and Installation
    442
  - Iat Sensor Inspection
    443
  - Iat Sensor Removal and Installation
    443
- Fuel Delivery System
  444
- Fuel System
  445
  - Fuel Tank Removal
    445
  - Fuel Tank Installation
    445
  - Fuel Pressure Inspection
    446
  - Fuel Pump Inspection
    447
  - Fuel Pump Relay Inspection
    448
  - Fuel Pump Removal and Disassembly
    450
  - Fuel Mesh Filter Inspection and Cleaning
    451
- Throttle Body
  454
  - Air Cleaner Box Removal
    455
  - Air Cleaner Box Installation
    455
  - Throttle Body Removal
    456
  - Throttle Body Disassembly
    457
  - Throttle Body Cleaning
    459
  - Fuel Injector Removal
    463
  - Fuel Injector Inspection
    464
  - Fuel Injector Installation
    464
  - Fast Idle
    465
  - Fast Idle Adjustment
    465
- Emission Control Systems
  471
  - Fuel Injection System
    471
  - Noise Emission Control System
    473
- Pair (Air Supply) System and Emission Control System Inspection
  474
  - Pcv Hose
    474
  - Pair Reed Valve
    474
  - Pair Control Solenoid Valve
    475
- EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
  476
- Tightening Torque
  477
- Wiring Harness, Cable and Hose Routing
  478
  - Cooling System Hose Routing
    482
  - Brake Pedal Installation
    485
- Pair (Air Supply) System Diagram
  486
- Pair (Air Supply) System Hose Routing
  487
- EVAP CANISTER HOSE ROUTING (Only for E-33)
  488
- Fuel Feed Hose Routing
  489
- Special Tools
  490
  - Vl800Tk5 ('05- Model)
    493
- Front Brake
  494
- Fuel System
  494
- Ignition Timing
  494
- Rear Suspension
  494
- Rear Tire Size
  494
- Trail
  494
- Battery
  501
- Headlight
  501
- 21/5W
  502
- High Beam Indicator Light
  502
- Neutral Indicator Light
  502
- Position/Parking Light
  502
- Speedometer Light
  502
- Turn Signal Indicator Light
  502
Vl800/Tk6 ('06-Model)

505
- Specifications
  
  506
- Service Data
  
  507
- Special Tools
  
  516
- Conrod/Crankshaft
  
  517
- Emission Control Systems
  
  522
Vl800/Tk7 ('07-Model)

523
- Fuel System
  524
- Clutch
  528
- Final Reduction Ratio
  528
  - MM (5.5 In)
    531
- Primary Reduction Ratio
  528
  - 2Nd
    528
  - 3Rd
    528
  - 4Th
    528
  - Top
    528
- Electrical
  
  531
  - Spark Plug
    531
  - Headlight
    531
  - Brake Light/Taillight
    532
    
    21/5 W
    532
  - Speedometer Light
    532
  - Turn Signal Indicator Light
    532
  - Neutral Indicator Light
    532
  - High Beam Indicator Light
    532
    
    Specifications
    532
    
    Fuel Pump and Fuel Level Gauge Removal
    535
    
    Fuel Pump and Fuel Level Gauge Installation
    536
    
    Fuel Level Meter Inspection
    536
    
    Fuel Level Gauge Inspection
    537
    
    Cable Routing
    538
    
    Front Brake Hose Routing
    539
- Service Data
  
  535
Vl800/C/ Tk9 ('09-Model)

542
- Periodic Maintenance Schedule
  545
- Fi System Diagnosis
  558
- Dtc Table and Defective Condition
  561
- Dtc Troubleshooting
  564
- Throttle Body Reassembly
  586
- Throttle Body Installation
  590
- Stp Sensor Adjustment
  591
- Tp Sensor Adjustment
  592
- Isc Valve Inspection
  593
- Isc Valve Installation
  593
- Isc Valve Removal
  593
- Isc Valve Preset and Opening Initialization
  594
- Throttle Valve Synchronization
  595
- Ignition System
  597
  - Inspection
    597
- Combination Meter Inspection
  600
  - Led (Light Emitting Diode)
    600
- Fuel Level Meter Inspection
  600
- Wiring Harness Routing
  601
  - MM (5.55 In)
    602
  - MM (5.43 In)
    602
- Cable Routing
  605
- Throttle Body Installation
  607
  - Spacer
    608
- Engine Mounting
  610
- Muffler & Exhaust Pipe Installation
  611
- Pair (Air Supply) System Hose Routing
  612
- Rear Combination Light Installation
  613
- Special Tools
  614
- Tightening Torque
  615
  - Engine
    615
  - Fi System and Intake Air System
    615
- Service Data
  616
  - 7° B.T.D.C. at 1 100 R/Min
    621
  - Spark Plug
    622
  - Position/Parking Light
    623
  - Brake Light/Taillight
    623
  - Speedometer Light
    623
  - Neutral Indicator Light
    623
  - High Beam Indicator Light
    623
  - Turn Signal Indicator Light
    623
  - Brake Disc
    623
- Emission Control System
  626
  - Exhaust Emission Control System (Pair System)
    626
  - EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
    627
- EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
  628
  - Evap System Purge Control Solenoid Valve
    628
  - Fuel Shut-Off Valve
    630
- HEATED OXYGEN SENSOR (HO2S) INSPECTION (for E-02, 19, 24, 33)
  628
- Pair (Air Supply) System Inspection
  628
- Pair (Air Supply) System Diagram
  631
- Pair (Air Supply) System Hose Routing
  631
- EVAP CANISTER HOSE ROUTING (Only for E-33)
  632
- Wiring Diagram
  633

Suzuki Intruder VL800 Manual (142 pages)

Brand: Suzuki | Category: Motorcycle | Size: 3.55 MB

Table of Contents

4
- The Sport of Motorcycling
  6
Fuel, Oil and Coolant Recommendations

14
- Fuel
  15
- Engine Oil
  17
- Gear Oil
  18
- Engine Coolant Solution
  19
Controls, Equipment and Adjustments

22
- Location of Parts
  23
- Ignition Switch
  26
- Key
  26
- Instrument Panel
  29
- Left Handlebar
  35
- Right Handlebar
  37
- Fuel Tank Cap
  39
- Gearshift Lever
  40
- Rear Brake Pedal
  40
- Helmet Holder
  41
- Side Stand
  41
- Suspension Adjustment
  42
- Break-In and Inspection before Riding
  46
Riding Tips

50
- Starting the Engine
  51
- Starting off and Shifting
  53
- Using the Transmission
  54
- Riding on Hills
  55
- Stopping and Parking
  55
- Carrying a Passenger
  57
Accessory Use and Motorcycle Loading

58
- Accessory Installation Guidelines
  59
- Accessory Use
  59
- Loading Limit
  60
- Loading Guidelines
  61
- Modification
  61
Inspection and Maintenance

62
- Inspection and Maintenance
  63
  - Maintenance Schedule
    63
  - Tools
    67
  - General Lubrication
    67
  - Battery
    68
  - Air Cleaner
    71
  - Spark Plug
    74
  - Engine Oil
    78
  - Engine Idle Speed Inspection
    83
  - Throttle Cable Adjustment
    83
  - Fuel Hose
    84
  - Clutch Adjustment
    86
  - Engine Coolant
    87
  - Final Gear Oil
    89
  - Brakes
    90
  - Tires
    96
  - Side Stand/Ignition Interlock System
    99
  - Front Wheel Removal
    100
  - Rear Wheel Removal
    102
  - Light Bulb Replacement
    104
  - Fuses
    107
  - Catalytic Converter
    109
- Troubleshooting
  112
Storage Procedure and Motorcycle Cleaning

116
- Storage Procedure
  117
- Corrosion Prevention
  118
- Procedure for Returning to Service
  118
- Motorcycle Cleaning
  119
- Inspection after Cleaning
  122
Consumer Information

124
- Consumer Information
  125
  - Warranties
    125
- Emission Control Systems
  126
- Tampering with Noise Control System Prohibited
  127
- Serial Number Location
  128
- Reporting Safety Defects
  129
- On-Board Motorcycle Computer Data Information
  130
- Location of Labels
  131
- Specifications
  135

Suzuki Intruder VL800 Owner's Manual (123 pages)

Brand: Suzuki | Category: Motorcycle | Size: 2.88 MB

Table of Contents

5
- The Sport of Motorcycling
  7
  - Most Accidents Can be Avoided
    8
- The Sport of Motorcycling
  8
Fuel, Oil and Coolant Recommendations

13
- Fuel
  14
- Engine Oil
  15
- Gear Oil
  16
- Engine Coolant Solution
  17
Controls, Equipment and Adjustments

19
- Location of Parts
  20
- Ignition Switch
  23
- Key
  23
- Instrument Panel
  25
- Left Handlebar
  31
- Right Handlebar
  33
- Fuel Tank Cap
  35
- Gearshift Lever
  36
- Rear Brake Pedal
  36
- Helmet Holder
  37
- Side Stand
  37
- Suspension Adjustment
  38
- Break-In and Inspection before Riding
  41
Riding Tips

45
- Riding Tips
  46
- Starting the Engine
  46
- Starting off and Shifting
  47
- Using the Transmission
  48
- Riding on Hills
  49
- Stopping and Parking
  49
- Carrying a Passenger
  51
Accessory Use and Motorcycle Loading

53
- Accessory Installation Guideline
  54
- Accessory Use
  54
- Loading Limit
  55
- Loading Guidelines
  56
- Modification
  56
Inspection and Maintenance

57
- Inspection and Maintenance
  58
- Maintenance Schedule
  58
- Notice
  58
- General Lubrication
  61
- Tools
  61
- Battery
  62
- Air Cleaner
  63
- Spark Plug
  67
- Engine Oil
  71
- Engine Idle Speed Inspection
  75
- Fuel Hose
  76
- Throttle Cable Adjustment
  76
- Clutch Adjustment
  78
- Engine Coolant
  79
- Final Gear Oil
  80
- Brakes
  81
- Tires
  86
- Side Stand/Ignition Interlock System
  90
- Front Wheel Removal
  91
- Rear Wheel Removal
  93
- Light Bulb Replacement
  95
- Fuses
  98
- Troubleshooting
  101
  - Troubleshooting
    102
Storage Procedure and Motorcycle Cleaning

105
- Storage Procedure
  106
- Procedure for Returning to Service
  107
- Corrosion Prevention
  108
- Motorcycle Cleaning
  109
- Inspection after Cleaning
  110
- Consumer Information
  111
  - Emission Control Warranty
    112
  - Tampering with Noise Control System Prohibited
    112
  - Serial Number Location
    113
  - Reporting Safety Defects
    114
  - On-Board Motorcycle Computer Data Information
    115
  - Location of Labels
    116
- Specifications
  118

Suzuki Intruder VL800 Supplementary Service Manual (144 pages)

Brand: Suzuki | Category: Motorcycle | Size: 13.13 MB

Table of Contents
3
Specifications
4
Abbreviations Used in this Manual
5
Sae-To-Former Suzuki Term
7
Service Data
9
- Oil Pump
  12
- Shaft Drive
  13
Periodic Maintenance Chart
19
Precautions in Servicing
20
Electrical Circuit Inspection Procedure
23
Fi System Technical Features
27
- Injection Stop Control
  28
- Fi System Parts Location
  29
- Fi System Wiring Diagram
  31
Self-Diagnosis Function
32
- Dealer Mode
  33
- Tps Adjustment
  35
Fail-Safe Function
36
Fi System Troubleshooting
37
Ecm Terminal
44
Malfunction Code and Defective Condition
45
Sensors
92
Stp Sensor Adjustment
93
Fuel Delivery System
94
Fuel System
95
Throttle Body
104
- Air Cleaner Box Removal
  105
- Air Cleaner Box Installation
  105
- Throttle Body Removal
  106
- Throttle Body Disassembly
  107
- Throttle Body Cleaning
  109
- Throttle Body Reassembly
  110
- Throttle Body Installation
  112
- Fuel Injector Removal
  113
- Fuel Injector Inspection
  114
- Fuel Injector Installation
  114
- Fast Idle
  115
- Fast Idle Adjustment
  115
- Throttle Valve Synchronization
  117
Emission Control Systems
121
Noise Emission Control System
123
Pair (Air Supply) System and Emission Control System Inspection
124
Pair Control Solenoid Valve
125
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
126
Tightening Torque
127
Wiring Harness, Cable and Hose Routing
128
- Cable Routing
  131
- Cooling System Hose Routing
  132
- Speed Sensor Lead Wire Routing
  133
- Fuel Tank Installation
  134
- Brake Pedal Installation
  135
Pair (Air Supply) System Diagram
136
Pair (Air Supply) System Hose Routing
137
EVAP CANISTER HOSE ROUTING (Only for E-33)
138
Special Tools
139
Wiring Diagram
141

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Vl800K5 ('05-Model)

Vl800/Tk6 ('06-Model)

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Vl800/Tk7 ('07-Model)

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Suzuki Intruder VL800 Manual (142 pages)

Table of Contents

Table of Contents

Fuel, Oil and Coolant Recommendations

Controls, Equipment and Adjustments

Riding Tips

Accessory Use and Motorcycle Loading

Inspection and Maintenance

Storage Procedure and Motorcycle Cleaning

Consumer Information

Suzuki Intruder VL800 Owner's Manual (123 pages)

Table of Contents

Table of Contents

Fuel, Oil and Coolant Recommendations

Controls, Equipment and Adjustments

Riding Tips

Accessory Use and Motorcycle Loading

Inspection and Maintenance

Storage Procedure and Motorcycle Cleaning

Suzuki Intruder VL800 Supplementary Service Manual (144 pages)

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