Suzuki 2004 VL800 Owner'S Manual Download Page 1

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Summary of Contents for 2004 VL800

Page 1: ...d _ _ d d _d l Y t d L l I _ _ J I i t t VL800 ii OWNER S MANUAL This owner s manual contains important safety information Plef3se read it carefully SUZUKI 1 d _ l...

Page 2: ...tate of Caliornia to cause cancer and birth defects or other reproductive harm t f This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold...

Page 3: ...OREWORD Motorcycling is one of the most exhilarating sports and to ensure your riding enjoyment you should become thoroughly familiar with the information presented in this Owner s Manual before ridin...

Page 4: ...engine coolant and other fluids batteries and tires COPYRIGHT SUZUKI MOTOR CORPORATION 2003 TABLE OF CONTENTS THE SPORT OF MOTORCYCLING 4 FUEL OIL AND COOLANT RECOMMENDATION 9 FUEL 9 ENGINE OIL 10 GEA...

Page 5: ...INTERLOCK SYSTEM 68 FRONT WHEEL REMOVAL 69 REAR WHEEL REMOVAL 70 LIGHT BULB REPLACEMENT 72 FUSES 75 TROUBLESHOOTING 77 STORAGE PROCEDURE 80 APPEARANCE CARE 82 CORROSION PREVENTION 82 MOTORCYCLE CLEANI...

Page 6: ...come better riders they also get more enjoyment fro the free dom unique to motorcycling Please remember Most accidents can be avoided The most common type of motor cycle accident in the U S occurs whe...

Page 7: ...and save your eyes from airborne hazards like bugs dirt or pebbles kicked up by tires If a collsion is imminent DO SOMETHING Many riders fear locking up their brakes or haven t learned to swerve to a...

Page 8: ...ull force braking is not the correct technique When the road surface is wet loose or rough you should brake with care When you re leaned over in a corner avoid braking Straighten up before braking Bet...

Page 9: ...oil film is washed away before riding Whenever in doubt about road conditions slow down Practice away from traffic Your riding skill and your mechan ical knowledge form the founda tion for safe riding...

Page 10: ...ncrease your riding enjoyment and safety You should read it thoroughly Be street smart Always heed speed limits local laws and the basic rules of the road Set a good example for oth ers by demonstrati...

Page 11: ...e ethanol content is not greater than 10 Gasoline Methanol Blends Fuel containing 5 or less metha nol wood alcohol may be suit able for use in your motorcycle if they contain co solvents and cor rosio...

Page 12: ...e painted surfaces Be careful not to spil any fuel when filing the fuel tank Wipe spiled gasoline up immedi ately ENGINE OIL Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which...

Page 13: ...Do not drink antifreeze or cool ant solution If swallowed do not induce vomiting Immedi ately contact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fres...

Page 14: ...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...

Page 15: ...LOCATION OF PARTS CD Q CD CI CD Clutch lever 2 Left handlebar switches Q Speedometer Front brake fluid reservoir Right handlebar switches Throttle grip Front brake lever CI Fuel tank cap 13...

Page 16: ...I I I I I I I I G j CI Throttle stop screw G Spark plug j Battery and main fuse j Tools Helmet holder Gearshift lever j Footrests f Choke knob CD Side stand Q Engine coolant reservoir i Fuses Passenge...

Page 17: ...i I I i 1 i I I I i i 0I 2 C Air cleaner Ignition switch Engine oil filler cap Engine oil inspection window Engine oil drain plug Engine oil filter j Rear brake light switch Rear brake pedal 15...

Page 18: ...are cut off The engine will not start The key can be removed ON position The ignition circuit is completed and the engine can be started The headlight and taillght will automatically turn on The key c...

Page 19: ...teering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Stop the motorcycle and place it on the side stand before lock ing the steering Never attempt t...

Page 20: ...clock odome ter and two trip meters When the ignition switch is turned to the ON position the display indi cates the test pattern shown below for three seconds Then the disply changes to odometer 000...

Page 21: ...zardous Removing a hand from the han dlebars can reduce your abilty to control the motorcycle Always keep both hands on the handlebars during operation Clock OdometerlTrip meters 2 2 Clock The clock i...

Page 22: ...ight Q The blue indicator light will come on when the headlight high beam is turned on Coolant Temperature Check Light 4 If this light comes on while riding it means that the coolant tempera ture is t...

Page 23: ...tor light lit can damage the engine and transmission Whenever the oil pressure indi cator lights up indicating low oil pressure stop the engine immediately Check the oil level and determine if the pro...

Page 24: ...s on Turn Signal Switch 4 Moving the switch to the 9 position wil flash the left turn sig nals Moving the switch to the q position will flash the right turn signals The indicator light wil also flash...

Page 25: ...brake lever is adjustable among 6 positions To change the position push the brake lever forward and turn the adjuster to the desired position Be sure the adjuster stops in the proper position a projec...

Page 26: ...c starter button to start the engine NOTE This motorcycle has a start er interlock system for the ignition and starter circuit The engine can only be started if The transmission is in neutral and the...

Page 27: ...level Filer neck AWARNING Overfilling the fuel tank can cause the fuel to overflow when it expands due to heat from the engine or the sun Spiled fuel can catch on fire Never fil the fuel above the bot...

Page 28: ...the choke knob GEARSHIFT LEVER This motorcycle has a 5 speed transmission which operates as shown To shift properly pull the clutch lever and close the throtte at the same time you operate the gearsh...

Page 29: ...e below the rear seat Insert the ignition key into the lock and turn it clockwise to open the latch Hook your helmet fastener ring to the latch and turn the key back to lock the holder AWARNING Riding...

Page 30: ...d If the engine is running and the transmission is shifted into gear with the side stand down the engine will stop running If the engine is running and the side stand is put down with the transmission...

Page 31: ...nt can be performed in seven posi tions To change the spring pre load setting follow the procedure below 1 Place the motorcycle on the side stand 2 Insert the ignition key into the lock and turn it cl...

Page 32: ...his break in period will help assure maximum life and perfor mance from your new motorcycle The following guidelines explain proper break in procedures Maximum Throttle Opening Recommendation The tabl...

Page 33: ...king for the first 160 km 100 miles Allow the Engine Oil to Circulate before Riding Allow enough idling time after warm or cold engine start up before revving the engine or plac ing the transmission i...

Page 34: ...e TIRES section in this owner s manuaL Check the condition of the motor cycle to help make sure that you do not have mechanical problems or get stranded somewhere when you ride Before riding the motor...

Page 35: ...Proper operation ignition inter loCkSystem General Bolts and nuts tightness condition No rattle frorn any parts of machine with the engine running No visible evidence of damage RIDING TIPS STARTING T...

Page 36: ...WARNING Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is color less and odorless and can cause death or severe injury Only run the engine o...

Page 37: ...t your control Reduce your speed and be alert to side winds Make sure that the side stand is in the fully up position Pull the clutch lever in and pause momen tarily Engage first gear by depressing th...

Page 38: ...for each gear Shifting up schedule Gear position miles h km h 1st 2nd 12 20 2nd 3rd 19 30 3rd 4th 25 40 4th Top 31 50 Shifting down schedule Gear position Top 4th Disengage the clutch when the motorc...

Page 39: ...wnshift through the gears as motorcycle speed decreases 4 Select neutral with the clutch lever squeezed toward the grip disengaged position just be fore the motorcycle stops Neutral position can be co...

Page 40: ...ere pedestrians or children are not likely to touch the muffler CARRYING A PASSENGER Before you invite someone to be a passenger on your motorcycle you need to be thoroughly familiar ith motorcycle op...

Page 41: ...uideline Install aerodynamic affecting accessories such as a fairing windshield backrests saddle bags and travel trunks as low as possible as close the motorcycle and as near the center of gravity as...

Page 42: ...o carry small items when you are not riding with a passenger Follow the guidelines below to carry a passenger or cargo Balance the load between the left and right side of the motor cycle and fasten it...

Page 43: ...Improper maintenance or fail ure to perform recommended maintenance increases the chance of an accident or motorcycle damage Always follow the inspection and maintenance recommen dations and schedule...

Page 44: ...n tenance more often than shown in the chart If you have any ques tions regarding maintenance intervals consult your SUZUKI dealer or qualified mechanic CAUTION Using poor qualiy replacement parts can...

Page 45: ...i Evaporative emission control system I i California model only Replace vaper hose every 4 years PAIR air supply system i I i Engine coolant Replace every 2 years Radiator hose I I I I Clutch i I I I...

Page 46: ...e motorcycle Increase fre quency when you use your motor cycle in severe conditions A tool kit is provided with your motorcycle The toolbox is located on the left side of the motorcycle To open the to...

Page 47: ...and Battery posts terminals and related accessories contain lead and lead compounds Hydrogen gas produced by batteries can explode if exposed to flames or sparks Keep flames and sparks away from the b...

Page 48: ...vide good engine power and gas mileage If you use your motorcycle under normal low stress conditions you should service the air cleaner at the inter vals specified If you ride in dusty wet or muddy co...

Page 49: ...element wil clog under these conditions and this may cause engine damage poor performance and poor fuel economy Clean the air cleaner case and element immediately if water gets in the air cleaner cas...

Page 50: ...er element for tears dur ing cleaning Replace it With a new one if it is torn Remove the plug and drain water and oil at the periodic ma inte nance intervaL The air cleaner drain plug is located benea...

Page 51: ...ct fit or heat range for your engine This may cause severe engine dam age which wil not be covered under warranty se one of the spark plugs listed below or equivalent Consult your authorized SUZUKI de...

Page 52: ...Spark Plugs Removal 1 Place the motorcycle on the side stand 3 Disconnect the coupler and 6 Disconnect the coupler CI remove the speedometer assembly 50...

Page 53: ...tool kit SPARK PLUG CLEANING II J To maintain a hot strong spark keep the plug free from carbon Remove carbon deposits from the plug with a wire or pin and adjust the gap to 0 8 0 9 mm 0 031 0 035 in...

Page 54: ...n open spark plug hole Cover the spark plug hole whenever the spark plug is removed ENGINE OIL Engine life depends on oil amount and quality Daily engine oil level checks and periodic changes are two...

Page 55: ...scheduled times The engine should always be warm when the engine oil is changed so the engine oil wil drain easily The procedure is as follows 1 Place the motorcycle on level ground on the side stand...

Page 56: ...oil filter with a Suzuki cap type oil filter wrench or a strap type filter wrench of proper size and remove the oil filter Keep new and used oil and solvent away from children and pets Wear a long sl...

Page 57: ...face a small resistance will be felt NOTE To tighten the oil fiter properly it is important to accu rately identify the positon at which the filer gasket first con tacts the mounting surface Mark top...

Page 58: ...win dow The oil level should be at the F full mark If it is lower than the F mark add oil until it reaches the F mark Inspect the areas around the drain plug and oil fiter for leaks CARBURETOR The ca...

Page 59: ...n play 5 Tighten the lock nut Q 6 While holding the throttle grip at the closed position turn out the adjuster 2 to feel resis tance 7 Tighten the lock nut CD Inadequate throttle cable play can cause...

Page 60: ...ne coolant solution should be between F full and L low level lines on the engine coolant reservoir If the level is lower than L low level line bring it up to F full level by add ing 50 50 mixture of d...

Page 61: ...mals Keep out of the reach of children and animals NOTE Adding only water wil dilute the engine coolant and reduce its effectiveness Add 50 50 mixture of engine coolant and water FINAL GEAR OIL Change...

Page 62: ...used oil and solvent away from children and pets Wear a long sleeve shirt and waterproof gloves Wash with soap if oil or sol vent contacts your skin NOTE Recycle or properly dis pose of used oil and s...

Page 63: ...f brake fluid If there is frequent loss of fluid take your motorcycle to a SUZUKI dealer or qualified mechanic for inspection Brake fluid is harmful or fatal if swallowed and harmful if it comes in co...

Page 64: ...the front brake pads to see if they are worn down to the grooved wear limit lines CD If a pad is worn to the grooved wear limit line it must be replaced with a new one After replacing the front brake...

Page 65: ...e following manner 4 Adjust the free travel to 20 30 mm 0 8 1 2 in by turning in or out the brake adjusting nut Q 1 Loosen the lock nut CD for the pedal stopper bolt 2 Adjust the brake pedal height by...

Page 66: ...While fully applying the brake check to see that the exten sion line of the index mark is within the range on the brake panel as shown in Fig A 3 If the extension line is out side this range as shown...

Page 67: ...sult in an accident due to tire failure The tires on your motorcycle form the cru ciallink between your motorcy cle and the road Follow these instructions Check tire condition and pressure and adjust...

Page 68: ...eck tire pressure each day before you ride acc rding to the table below Tire pressure should only be checked and adjusted before riding since riding wil heat up the tires and lead to higher inflation...

Page 69: ...rcycle han dling may be adversely affected possibly resulting in loss of motor cycle control FRONT REAR SIZE 130 90 16 170 80 15 M C 67H M C 77H TYPE IRC GS 23F fRC GS 23R NOTE Motorcycle tires have t...

Page 70: ...ystem is working properly 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 ing properly Have your motorcy...

Page 71: ...nt wheel is slightly off the ground CAUTION Improper jacking may cause damage to the oil filter Do not apply the jack head to the oil filter when jacking up the motorcycle 5 Slide the front wheel forw...

Page 72: ...the proper specifications If you are not sure of the proper pro cedure have your authorized SUZUKI dealer or qualified mechanic do this Front axle tightening torque 65 N m 6 5 kgf m 47 0 Ib ft Front a...

Page 73: ...r cools to avoid burns 4 Place an accessory service stand or equivalent under the swing arm or chassis tubes to stabilze the rear end 6 Remove the wheel from the splined drive gear and set the wheel a...

Page 74: ...ing torque 65 N m 6 5 kgf m 47 0 Ib ft Rear brake caliper holder mount ing nut tightening torque 39 N m 3 9 kgf m 28 0 Ib ft LIGHT BULB REPLACEMENT The wattage rating of each bulb is shown in the foll...

Page 75: ...ocket 2 from the headlight and rubber cap Q 3 Unhook bulb holder spring 4 and pull out the bulb CAUTION Oil from your skin may damage the headlight bulb or shorten its life Grasp the new bulb with a c...

Page 76: ...rn Signal Light To adjust the beam horizontally Turn the adjuster CD clockwise or counterclockwise 1 Remove the screw CD To adjust the beam vertically Turn the adjuster C clockwise or counterclockwise...

Page 77: ...ON Overtightening the screws may cause the lens to crack Tighten the screws only until they are snug FUSES MAIN FUSE The main fuse is located under the front seat To access the fuse remove the seat by...

Page 78: ...instead of a fuse may seriously damage the electrical system Always replace a blown fuse with a fuse of the same type and rating If the new fuse blows in a short time consult your SUZUKI dealer or qu...

Page 79: ...urn signal light 10A POWER SOURCE fuse protects the electrical acces sories connect d to output ter minaL TROUBLESHOOTING This troubleshooting guide is pro vided to help you find the cause of some com...

Page 80: ...mes sparks and heat sources away Drain fuel only outdoors or in a well ventilated area Do not smoke Wipe up spils immediately Avoid breathing fuel vapor Keep children and pets away Dispose of drained...

Page 81: ...g the spark test improperly can cause a high voltage electrical shock or an explosion Avoid performing this check if you are not familiar with this procedure or if you have a heart condition or wear a...

Page 82: ...ace where it will not fall over FUEL 1 Fill the fuel tank to the top with fuel mixed with the amount of gasoline stabilizer recom mended by the stabilzer man ufacturer 2 Drain the carburetor or run th...

Page 83: ...oap and remove corrosion from the ter minals and wiring harness 3 Store the battery in a room above freezing TIRES Inflate the tires to the normal specifications MAINTENANCE DURING STORAGE Once a mont...

Page 84: ...ly at least once a month Keep your motorcycle as clean and dry as possible Remove foreign material deposits Foreign material such as road salt chemicals road oil or tar tree sap bird droppings and ind...

Page 85: ...r pollution reaching the surface Your Suzuki dealer can help you select the right cover for your motorcy cle MOTORCYCLE CLEANING Washing the Motorcycle When washing the motorcycle follow the instructi...

Page 86: ...ct and beautify the paint Observe the precautions speci fied by the wax manufacturer INSPECTION AFTER CLEANING For extended life of your motorcy cle lubricate according to GEN ERAL LUBRICATION section...

Page 87: ...lass i 50 to 169 cc 12000 km 7456 miles Class I 170 to 279 cc 18000 km 11185 miles Class II 280 cc and 30000 km over 18641 miles Failures other than those result ing from defects in material or workma...

Page 88: ...puncturing the air cleaner case air cleaner cover baffles or any other component which conducts intake air Whenever replacing parts on your motorcycle Suzuki recommends that you use genuine Suzuki re...

Page 89: ...ms between you your authorized Suzuki dealer or American Suzuki Motor Corp To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area o...

Page 90: ...rter system Electric Lubrication system Wet sump DRIVE TRAIN Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattem 1 down 4 up Primary reduction ratio 1 690 71 42 Final reduc...

Page 91: ...ght ailight 12V 21 5W Front turn signal 12V 21 5W Rear turn signal 12V 21W Speedorneter light LED Neutral indicator light LED High beam indicator Iight LED Turn signal indicator light LED Oil pressure...

Page 92: ...ective clothing Don t ride after consuming al cohol or other drugs Slow down on slippery sur faces unfamiliar terrain or when visibilty is reduced Read owner s manual care fully IIIIIIIIIIIIIIIII IIII...

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Summary of Contents for 2004 VL800

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Suzuki 2004 VL800, Owner'S Manual

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Summary of Contents for 2004 VL800

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