User Manuals: Suzuki VZR1800 2008 Motorcycle

Manuals and User Guides for Suzuki VZR1800 2008 Motorcycle. We have 1 Suzuki VZR1800 2008 Motorcycle manual available for free PDF download: Service Manual

Suzuki VZR1800 2008 Service Manual

Suzuki VZR1800 2008 Service Manual (609 pages)

Brand: Suzuki | Category: Motorcycle | Size: 54.07 MB

Table of Contents

General Information 1

12
- Table of Contents
  12
- Warning/Caution/Note
  13
- General Precautions
  13
- Suzuki Vzr1800K6 ('06-Model)
  15
- Serial Number Location
  15
- Fuel, Oil and Engine Coolant Recommendation
  16
  - Fuel (for Usa and Canada)
    16
  - Fuel (for Other Countries)
    16
  - Engine Oil (for Usa)
    16
  - Engine Oil (for Other Countries)
    16
  - Gear Oil (Final Drive Gear Oil)
    16
  - Brake Fluid
    16
  - Front Fork Oil
    17
  - Engine Coolant
    17
- Break-In Procedures
  18
- Cylinder Identification
  18
- Information Labels
  19
- Specifications
  20
  - Dimensions and Dry Mass
    20
  - Engine
    20
  - Drive Train
    20
  - Chassis
    21
  - Electrical
    21
  - Capacities
    21
Periodic Maintenance

22
- Periodic Maintenance Schedule
  23
  - Periodic Maintenance Chart
    23
  - Lubrication Points
    24
- Maintenance and Tune-Up Procedures
  25
  - Air Cleaner
    25
  - Exhaust Pipe Bolts and Muffler Bolts
    27
  - Exhaust Control Valve
    28
  - Valve Clearance
    29
  - Spark Plug
    34
  - Fuel Line
    37
  - Evaporative Emission Control System (E-33 Only)
    37
  - Engine Oil and Oil Filter
    38
  - Final Gear Oil
    40
  - Throttle Cable Play
    40
  - Pair (Air Supply) System
    40
  - Throttle Valve Synchronization
    41
  - Cooling System
    41
  - Clutch Cable Play
    43
  - Brake
    44
  - Tires
    48
  - Steering
    49
  - Front Fork
    49
  - Rear Suspension
    50
  - Chassis Bolts and Nuts
    50
- Compression Pressure Check
  52
  - Compression Test Procedure
    52
- Oil Pressure Check
  53
- Sds Check
  54
Engine

58
- Engine Removal and Installation
  60
  - Engine Removal
    60
  - Engine Installation
    66
- Engine Disassembly
  70
- Engine Components Inspection and Service
  86
  - Cylinder Head Cover
    86
  - Camshaft
    86
  - Cam Chain Tension Adjuster
    89
  - Cam Chain Tensioner
    89
  - Cam Chain Guide
    89
  - Cylinder Head and Valve
    89
  - Cylinder
    98
  - Piston and Piston Ring
    99
  - Clutch
    101
  - Gearshift Cover
    103
  - Starter Clutch
    104
  - Oil Pump
    105
  - Starter Torque Limiter
    107
  - Generator Cover
    107
  - Clutch Release Camshaft
    108
  - Water Pump
    109
  - Gearshift
    109
  - Oil Pressure Regulator
    110
  - Oil Strainer
    110
  - Transmission
    111
  - Crankcase
    117
  - Balancer Driven Gear
    124
  - Crankshaft and Conrod
    126
  - Crankshaft Journal Bearing
    130
  - Crankshaft Thrust Bearing
    133
- Engine Reassembly
  135
Driveline/Axle

172
- Secondary Bevel Gears
  173
  - Construction
    173
  - Removal
    175
  - Disassembly
    175
  - Inspection
    177
  - Reassembly
    179
  - Secondary Gear Shims Adjustment
    181
- Final Bevel Gears
  184
  - Construction
    184
  - Final Gear Case Removal
    186
  - Final Gear Case Disassembly
    186
  - Final Gear Shims Adjustment
    191
  - Final Gear Case Reassembly
    195
  - Final Gear Case Installation
    199
Fi System Diagnosis

202
Fuel System and Throttle Body

302
- Fuel Delivery System
  303
- Fuel System
  304
  - Fuel Tank Removal
    304
  - Fuel Tank Installation
    304
  - Fuel Pressure Inspection
    305
  - Fuel Pump Inspection
    306
  - Fuel Discharge Amount Inspection
    306
  - Fuel Pump Relay Inspection
    307
  - Fuel Pump and Fuel Level Gauge Removal
    308
  - Fuel Level Gauge Inspection
    309
  - Fuel Pump Disassembly
    310
  - Fuel Mesh Filter Inspection
    311
  - Fuel Pump and Fuel Level Gauge Reassembly and Installation
    311
- Throttle Body
  313
  - Construction
    313
  - Air Cleaner Box Removal
    314
  - Air Cleaner Box Installation
    314
  - Air Cleaner Chamber and Throttle Body Removal
    314
  - Throttle Body Disassembly
    316
  - Throttle Body Cleaning
    318
  - Inspection
    318
  - Isc Valve Inspection
    318
  - Isc Valve Removal
    319
  - Inspection
    319
  - Isc Valve Installation
    319
  - Throttle Body Reassembly
    320
  - Air Cleaner Chamber and Throttle Body Installation
    322
  - Stp Sensor Adjustment
    323
  - Fuel Injector Removal
    323
  - Fuel Injector Inspection
    323
  - Fuel Injector Installation
    324
  - Throttle Valve Synchronization
    324
  - Throttle Position Sensor (Tps) Setting
    325
Exhaust System

326
- Excva (Exhaust Control Valve Actuator) and Excv (Exhaust Control Valve)
  327
  - Excva and Excv Removal
    327
  - Excva Inspection
    328
  - Excv Inspection
    328
  - Cable Inspection
    328
  - Excva and Excv Installation
    329
  - Excva Adjustment
    331
- Exhaust Pipe and Muffler
  333
  - Removal
    333
  - Installation
    335
Cooling and Lubrication System

338
- Engine Coolant
  339
- Cooling Circuit
  340
  - Cooling Circuit Inspection
    340
- Radiator and Water Hose
  341
  - Radiator Removal and Disassembly
    341
  - Radiator Disassembly
    342
  - Radiator Cap Inspection
    342
  - Radiator Inspection and Cleaning
    343
  - Radiator Reassembly
    343
  - Radiator Installation
    343
  - Water Hose Inspection
    344
- Cooling Fan
  345
  - Inspection
    345
  - Cooling Fan Relay Inspection
    345
- Ect Sensor
  346
  - Removal
    346
  - Inspection
    346
  - Installation
    347
- Thermostat
  348
  - Removal
    348
  - Inspection
    348
  - Installation
    349
- Water Pump
  350
  - Removal and Disassembly
    350
  - Inspection
    352
  - Reassembly and Installation
    353
- Engine Lubrication System Chart
  356
Chassis

358
- Exterior Parts
  360
  - Fastener Removal and Installation
    360
  - Front and Rear Seat
    361
  - Frame Side Cover
    362
  - Rear Frame Cover
    362
  - Frame Head Cover and Radiator Cover
    363
- Front Wheel
  365
  - Construction
    365
  - Removal
    366
  - Inspection and Disassembly
    366
  - Reassembly and Installation
    368
- Front Fork
  371
  - Construction
    371
  - Removal and Disassembly
    372
  - Inspection
    375
  - Reassembly
    376
  - Installation
    379
- Steering
  380
  - Construction
    380
  - Removal
    381
  - Inspection and Disassembly
    382
  - Reassembly
    383
  - Installation
    383
  - Steering Tension Adjustment
    385
- Handlebars
  386
  - Construction
    386
  - Removal
    387
  - Installation
    388
- Rear Wheel
  390
  - Construction
    390
  - Removal
    391
  - Disassembly
    391
  - Inspection and Disassembly
    392
  - Reassembly and Installation
    393
- Rear Suspension
  397
  - Construction
    397
  - Removal
    398
  - Inspection and Disassembly
    399
  - Rear Shock Absorber Disposal
    402
  - Reassembly
    403
  - Installation
    406
  - Suspension Setting
    407
- Front Brake
  408
  - Construction
    408
  - Brake Pad Replacement
    409
  - Brake Fluid Replacement
    410
  - Caliper Removal
    411
  - Caliper Disassembly
    412
  - Caliper Inspection
    413
  - Caliper Reassembly
    413
  - Caliper Installation
    415
  - Brake Disc Inspection
    415
  - Master Cylinder Removal and Disassembly
    416
  - Master Cylinder Inspection
    417
  - Master Cylinder Reassembly
    417
  - Master Cylinder Installation
    418
- Rear Brake
  419
  - Construction
    419
  - Brake Pad Replacement
    420
  - Brake Fluid Replacement
    421
  - Caliper Removal
    422
  - Caliper Disassembly
    422
  - Caliper Inspection
    423
  - Caliper Reassembly
    425
  - Caliper Installation
    426
  - Master Cylinder Removal
    426
  - Master Cylinder Disassembly
    427
  - Master Cylinder Inspection
    428
  - Master Cylinder Reassembly
    428
  - Master Cylinder Installation
    429
- Tire and Wheel
  430
  - Tire Removal
    430
  - Inspection
    430
  - Valve Inspection
    431
  - Tire Installation
    432
  - Balancer Weight Installation
    433
Electrical System

434
- Cautions in Servicing
  436
  - Connector
    436
  - Coupler
    436
  - Clamp
    436
  - Fuse
    436
  - Semi-Conductor Equipped Part
    437
  - Battery
    437
  - Connecting the Battery
    437
  - Wiring Procedure
    437
  - Using the Multi-Circuit Tester
    438
- Location of Electrical Components
  439
- Charging System
  441
  - Troubleshooting
    441
  - Inspection
    442
- Starter System and Side-Stand/Ignition Interlock System
  445
  - Troubleshooting
    445
  - Starter Motor Removal
    447
  - Starter Motor Inspection
    449
  - Starter Motor Reassembly
    450
  - Starter Relay Inspection
    451
  - Side Stand/Ignition Interlock System Parts Inspection
    452
- Ignition System
  455
  - Troubleshooting
    456
  - Inspection
    458
- Speedometer and Tachometer
  463
  - Description
    463
  - Speedometer Removal and Disassembly
    464
  - Tachometer Removal and Disassembly
    465
  - Inspection
    466
  - Headlight Relay Inspection
    473
- Relays
  474
  - Turn Signal/Side-Stand Relay
    474
  - Starter Relay
    474
  - Fuel Pump Relay
    474
  - Cooling Fan Relay
    474
  - Switches Inspection
    475
- Battery
  476
  - Specifications
    476
  - Initial Charging
    476
  - Servicing
    478
  - Recharging Operation
    478
Servicing Information

480
- Troubleshooting
  482
  - Fi System Malfunction Code and Defective Condition
    482
  - Engine
    486
  - Radiator (Cooling System)
    492
  - Chassis
    493
  - Shaft Drive
    494
  - Brakes
    494
  - Electrical
    495
  - Battery
    496
  - Special Tools
    497
- Tightening Torque
  501
  - Cooling System
    502
  - Tightening Torque Chart
    504
- Service Data
  505
- Wiring Harness, Cable and Hose Routing
  514
  - Wiring Harness Routing
    514
  - Engine Electrical Parts Lead Wire Routing
    516
  - Cable Routing
    517
  - Front Brake Hose Routing
    518
  - Rear Brake Hose Routing
    519
  - Throttle Body Hose Routing
    520
  - Cooling System Hose Routing
    521
  - Pair (Air Supply) System Hose Routing (for E-03, 28, 33)
    522
  - Pair (Air Supply) System Hose Routing (for the Others)
    523
  - Fuel Tank Installation
    524
  - Frame Head Cover and Radiator Cover Installation
    525
  - Frame Head Cover Cushion Installation
    526
  - Radiator Upper Cover Cushion Installation
    526
  - Left Frame Covers Installation
    527
  - Right Frame Covers Installation
    528
  - Headlight Cover Installation
    529
  - Ignition Coil Installation
    530
  - Side-Stand Installation
    530
  - Rear Turn Signal Light, License Light Wire Routing
    531
  - Seat Lock Cable Routing
    531
  - License Light and License Plate Installation
    532
  - Brake Light/Taillight Installation
    532
Emission Control Information

534
Specifications

547
- Brake Light/Taillight
  554
- Coolant Temperature/Oil Pressure Indicator Light
  554
  - Service Data
    564
  - Fi System Wiring Diagram
    573
  - Ecm Terminal
    574
  - Fail-Safe Function
    576
  - Malfunction Code and Defective Condition
    577
  - Isc Valve Reset
    579
  - C44" (P0156) or "C64" (P0130) O2 SENSOR (O2S) CIRCUIT
    580
  - Malfunction (for E-02, 19, 24, 51)
    580
  - C49" (P1768) or "C61" (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
    583
  - Wiring Diagram
    584
  - Cable Routing
    586
  - Headlight
    596
  - Position Light
    596
  - Brake Light/Taillight
    596
  - Front Turn Signal Light
    596
  - Rear Turn Signal Light
    596
  - License Light
    596
  - High Beam Indicator Light
    596
  - Turn Signal Indicator Light
    596
  - Neutral Indicator Light
    596
  - Coolant Temperature/Oil Pressure Indicator Light
    596
  - Specifications
    598
  - Rear Wheel
    599
  - Headlight Beam Adjustment
    600
  - Wiring Diagram
    601
  - Wiring Harness Routing
    603
  - Front Brake Hose Routing
    605
- Front Turn Signal Light
  554
- Front Turn Signal Light/Position Light
  554
- High Beam Indicator Light
  554
- License Light
  554
- Neutral Indicator Light
  554
- Position Light
  554
- Rear Turn Signal Light
  554
- Turn Signal Indicator Light
  554

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