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Suzuki 2005 VL1500K5, Supplementary Service Manual, Page: 3 / 181

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Suzuki 2005 VL1500K5 Supplementary Service Manual Download Page 3

2      VL1500K5 (’05-MODEL) 

SWITCHES........................................................................................................ 142
BATTERY.......................................................................................................... 143
WIRING HARNESS, CABLE AND HOSE ROUTING....................................... 144
EXTERIOR PARTS INSTALLATION................................................................ 153
SPECIAL TOOLS.............................................................................................. 157
TIGHTENING TORQUE .................................................................................... 158
SERVICE DATA ................................................................................................ 159
EMISSION CONTROL SYSTEMS .................................................................... 168
PAIR (AIR SUPPLY) SYSTEM INSPECTION .................................................. 172
PAIR (AIR SUPPLY) SYSTEM DIAGRAM ....................................................... 174
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................................ 175
HEATED OXGEN SENSOR (HO2S) INSPECTION (FOR E-02, 19, 24) .......... 176
WIRING DIAGRAM ........................................................................................... 177

COUNTRY AND AREA CODES

The following codes stand for the applicable country (-ies) and area (-s).

CODE

COUNTRY or AREA

EFFECTIVE FRAME NO.

E-03
E-19
E-24
E-28
E-33

U.S.A. (Except for California)

EU

Australia

Canada

California (U.S.A.)

JS1VY52A 52100001 –
JS1AL211100105237 –
JS1AL211300100688 –
JS1VY52A 52100001 –
JS1VY52A 52100001 –

SA

MP

LE

Summary of Contents for 2005 VL1500K5

Page 1: ...VL1500 USE THIS MANUAL WITH VL1500 SERVICE MANUAL 99500 39166 01E...

Page 2: ...ULE 7 MAINTENANCE AND TUNE UP PROCEDURES 8 ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 13 ENGINE REMOVAL AND INSTALLATION 14 ENGINE DISASSEMBLY AND REASSEMBLY 17 ENGINE COMPONENTS INSPECTION AND...

Page 3: ...PLY SYSTEM DIAGRAM 174 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 175 HEATED OXGEN SENSOR HO2S INSPECTION FOR E 02 19 24 176 WIRING DIAGRAM 177 COUNTRY AND AREA CODES The following codes stand for the applic...

Page 4: ...nit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit EOT Sensor Engine Oil Tempe...

Page 5: ...ry Air Injection PCV Positive Crankcase Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers STC System Secondary Throttle Control System STCS STP...

Page 6: ...780 in Stroke 101 mm 3 976 in Displacement 1 462 cm3 89 2 cu in Compression ratio 8 5 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet...

Page 7: ...9 or DENSO X22EPR U9 Battery 12 V 64 8 kC 18 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 15 15 10 A Headlight 12 V 60 55 W H4 Position Parking light 12 V 5 W Except E 03...

Page 8: ...500 11 000 14 500 months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe nuts and muffler bolts T T T Spark plugs I R I R Fuel hose I I I I Replace every 4 years Engine oil R R R R R Engine oi...

Page 9: ...ct the fuel feed hose A for damage and fuel leakage If any defect is found the fuel feed hose must be replaced ENGINE IDLE SPEED NOTE Warm up the engine before adjusting the engine idle speed Adjust t...

Page 10: ...lock nut 4 while holding the adjuster 6 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable 2 until resistance is fe...

Page 11: ...0 16 in While holding the throttle grip at the fully closed position slowly turn the returning cable adjuster 2 to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut 1 securely THROTTLE VALVE SYNC...

Page 12: ...ffler mounting bolts to the specified torque Tighten initially at 1 000 km 600 miles 2 month and every 12 000 km 7 500 miles 24 months thereafter Apply PERMATEX 1372 Apply PERMATEX 1372 A Gasket ITEM...

Page 13: ...5 Brake hose union bolt 23 2 3 16 5 Front brake hose joint nut 15 1 5 11 0 Front brake hose adaptor 23 2 3 16 5 Air bleeder valve 7 5 0 75 5 5 Handlebar set bolt 23 2 3 16 5 Handlebar holder nut 70 7...

Page 14: ...6 Starter idle gear 3 17 3D 1 3 60 3D 6 Starter clutch 3 27 3D 1 3D 5 3 38 3D 5 3D 6 Gearshift lever and linkage 3 26 3E 1 3 38 3E 5 Generator 3 27 3D 1 3 38 3D 6 PARTS REMOVAL INSTALLATION Clutch cov...

Page 15: ...DEL For details other than the removal pro cedure refer to the VL1500 Service Manual Remove the seats Page 121 Remove the PAIR cover 1 Disconnect the PAIR hoses 2 from the pipes Remove the PAIR contro...

Page 16: ...VL1500K5 05 MODEL 15 Remove the PAIR device bracket 7 Remove the No 1 and No 2 PAIR pipes Remove the air cleaner box Page 103 Remove the throttle body Page 104 SAMPLE...

Page 17: ...ollowing items to the specification Engine oil VL1500 Service Manual 2 6 Throttle valve synchronization Page 114 Throttle cable play Page 9 Engine idle speed Page 8 Automatic decompression cable VL150...

Page 18: ...ch 1 align the pin A with the hole B in the gearshift cam retainer 2 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others EOT SENSOR REMOVAL Place an oil pan below the EOT se...

Page 19: ...ng refer to the VL1500 Service Manual Each camshaft I D code has been changed which is stamped on the camshaft end CAM WEAR Cam height H Service Limit IN 35 02 mm 1 379 in EX 36 58 mm 1 440 in 09900 2...

Page 20: ...sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminal...

Page 21: ...nector for excessive opening Also check the coupler for locking loose ness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a f...

Page 22: ...will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a low volt...

Page 23: ...ion Also check for condition of the coupler lock if equipped Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poo...

Page 24: ...hecked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measu...

Page 25: ...ose parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to groun...

Page 26: ...h the multi circuit tester will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After u...

Page 27: ...various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Crankshaft Po...

Page 28: ...operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in...

Page 29: ...ssure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm 43 psi the fuel is injected...

Page 30: ...switch B Starter relay I HO2 sensor HO2S For E 02 19 24 C Starter motor J Crankshaft position sensor CKPS D Intake air pressure sensor 1 IAPS K Fuel injector 2 FI E Fuel pump relay FP RELAY L Fuel in...

Page 31: ...n solenoid O Secondary throttle position sensor STPS T Intake air temperature sensor IATS P Throttle position sensor TPS U Ignition coil 2 IG COIL Q Secondary throttle valve actuator STVA V PAIR solen...

Page 32: ...sition switch Gear position switch Starter button Ignition coil IG COIL ECM Crankshaft position sensor CKPS Throttle position sensor TPS Secondary throttle position sensor STPS Intake air pressure sen...

Page 33: ...r signal CKP P Neutral switch NT 0 Power source for fuel injector VM Q CKP sensor signal CKP A Power source B 1 R B Power source for back up B 2 S Blank C ECM ground E1 T Blank D Sensors ground E2 U S...

Page 34: ...itch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 secon...

Page 35: ...ces These affected devices are indicated in the code form 09930 82720 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the ECM...

Page 36: ...re indicated alternately CODE MALFUNCTION PART REMARKS C00 C12 C13 C14 C15 C17 C18 C19 C21 C23 C24 C25 C28 C29 C31 C32 C33 C41 C42 C44 C49 None Crankshaft position sensor CKPS Intake air pressure sens...

Page 37: ...r VL1500 Service Manual 6 3 4 Loosen the screw and turn the throttle position sensor 1 and bring the line to the middle 5 Then tighten the screws to fix the throttle position sensor 09930 11950 Torx w...

Page 38: ...sor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES EOT sensor Engine oil temperature value is fixed to 80 C 176 F YES YES IAT sensor Intake air temperature v...

Page 39: ...on LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult Starting P...

Page 40: ...fuse FI light operation Page 33 and 140 Each warning light operation Page 140 Speedometer operation Page 141 Exhaust gas leakage and noise Page 11 Each coupler disconnection Clogged oil cooler fins V...

Page 41: ...Service Manual 6 3 Connect the special tool to the dealer mode coupler at the wir ing harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and che...

Page 42: ...19 before inspection and observe what is written there Remove the left side frame head cover VL1500 Service Manual 6 3 Set up the SDS tool Refer to the SDS operation manual for further details Read th...

Page 43: ...ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wir...

Page 44: ...opped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a funct...

Page 45: ...indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified...

Page 46: ...fied value TO sensor circuit shorted to ground or VCC circuit open C24 C25 Ignition sig nal CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 8 times or more con...

Page 47: ...turned ON or voltage is applied to fuel pump Fuel pump relay lead wire cou pler connection power source to the fuel pump relay and fuel injectors P0230 although fuel pump relay is turned OFF C42 Igni...

Page 48: ...r loose or poor contacts If OK then measure the CKP sensor resistance 6 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 178 242 Green Blue DETECTED CONDITION POSSIB...

Page 49: ...lt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool Page 42 YES Go to step 2 NO Replace the CKP...

Page 50: ...ON 6 Measure the voltage at the Red wire 3 and ground 7 Also measure the voltage at the Red wire 3 and B Br wire 4 IAP sensor input voltage 4 5 5 5 V Red Ground Red B Br 09900 25008 Multi circuit tes...

Page 51: ...dle speed Front cylinder side G B B Br Rear cylinder side G W B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 4 After re...

Page 52: ...011 Vacuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool Page 42 YES Red B Br or G B wire...

Page 53: ...p 20 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 4 4 0 2 001 5 000 611 1 524 707 634 94 85 2 8 3 7 5 001 8 000 1 525 2 438 634 56...

Page 54: ...set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following range Difference between actual throttle open ing and opening cal...

Page 55: ...ster the circuit condition is OK 6 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 7 Check the continuity between BI B wire A and terminal K 8 Also check the...

Page 56: ...from the tester the circuit condi tion is OK 7 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between BI B wire A and terminal K 9 Al...

Page 57: ...istance Throttle valve is closed Approx 1 12 k Throttle valve is opened Approx 4 41 k 7 If OK then measure the TP sensor resistance at the test har ness terminals between terminal c and terminal D TP...

Page 58: ...uit tester set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool Page 42 3 V ECM TPS BI B R B Br 3 YES R B Br or BI B wire open or shorted to...

Page 59: ...Ground B Bl B G 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage is not within the following range 0 1 Sensor...

Page 60: ...etween B Bl wire A and terminal I 6 Also check the continuity between B G wire B and terminal D EOTS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed pro...

Page 61: ...is OK Tester knob indication Continuity test 5 Connect the EOT sensor coupler and turn the ignition switch ON 6 Measure the voltage between B Bl wire 1 and ground EOT sensor output voltage 0 1 4 6 V B...

Page 62: ...age 42 EOT sensor specification YES B Bl or B Br wire open or shorted to ground or poor D or I connection Open or short circuit in the sub harness or sab harness connection If wire and connection are...

Page 63: ...lue does not change in the propor tion indicated replace it with a new one EOT sensor specification 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is noted to...

Page 64: ...DETECTED CONDITION POSSIBLE CAUSE Decomp relay signal is not input to ECM Decomp system circuit open or short ECM malfunction ECM Decomp solenoid Side stand relay Ignition switch Decomp relay Engine s...

Page 65: ...ls 2 Turn the ignition switch ON 3 Click Decomp sol operating control 1 4 With the engine starter button pushed click On button 2 At this time if an operation sound is heard from the decomp solenoid v...

Page 66: ...42 DETECTED CONDITION POSSIBLE CAUSE Starter relay signal is not input to ECM Starter system circuit open or short ECM malfunction ECM Side stand relay Ignition switch Engine stop switch STRL Y G O W...

Page 67: ...and B Br wire terminal 2 IAT sensor input voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C...

Page 68: ...ce Manual 6 3 5 Disconnect the IAT sensor coupler and ECM coupler 6 Check the continuity between Dg wire A and terminal 2 7 Also check the continuity between B Br wire B and terminal D IATS lead wire...

Page 69: ...nd is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Measure the voltage between Dg wir...

Page 70: ...way as that of the EOT sensor Refer to page 62 for details 1 YES Dg or B Br wire open or shorted to ground or poor 2 or D connection If wire and connection are OK intermittent trou ble or faulty ECM R...

Page 71: ...circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the follow ing for 2 sec and more after ignition switch is...

Page 72: ...condition is OK 6 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 7 Check the continuity between Br W wire B and terminal J 8 Also check the continuity betwe...

Page 73: ...e tester the circuit condi tion is OK 7 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between Red wire A and terminal 6 9 Also then...

Page 74: ...9 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool Page 42 C24 P0351 or C25 P0352 IGNITION SYSTEM MALFUNCTION When i...

Page 75: ...operating OK 5 After repairing the trouble clear the DTC using SDS tool Page 42 DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA ECM does not receive communication signa...

Page 76: ...B D 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 5 After repairing the trouble clear the DTC using SDS tool Page 42 2 2 YES B Lg P W Green and W B wire o...

Page 77: ...the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control 1 4 Click each button 2 At this time if an operation soun...

Page 78: ...indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is...

Page 79: ...rcuit condition is OK 6 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 7 Check the continuity between Y W wire B and terminal 4 8 Also check the continuity...

Page 80: ...ester the circuit condi tion is OK 7 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between Y W wire B and terminal 4 9 Also check th...

Page 81: ...e the valve closing and opening resistance STP sensor resistance Secondary throttle valve is closed Approx 0 5 k Secondary throttle valve is opened Approx 3 9 k Yellow A Black B 7 If OK then measure t...

Page 82: ...prox 0 5 V Secondary throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 7 After repairing...

Page 83: ...ignition switch ON 9 Measure the voltage at the wire side coupler between R B wire and B G wire when shifting the gearshift lever from 1st to Top GP switch voltage 0 6 V and more R B B G 09900 25008...

Page 84: ...ntermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO R B or B G wire open or R B...

Page 85: ...side 2 for loose or poor contacts If OK then measure the injector resistance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance Approx 11 7 at 20 C 68 F...

Page 86: ...ds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool Page 42 YES Go to...

Page 87: ...pplied to fuel pump although fuel pump relay is turned OFF Fuel pump relay circuit open or short Fuel pump relay malfunction ECM malfunction YES Yellow or O W wire open or shorted to ground or poor e...

Page 88: ...s not heard from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE C44 P0130 HO2 sensor output volta...

Page 89: ...44 P0130 1 Connect the ECM coupler and HO2 sensor coupler 2 Warm up the engine enough 3 Measure the HO2 sensor output voltage between W G wire and B Br wire when idling condition HO2 sensor output vol...

Page 90: ...affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 5 After repairing t...

Page 91: ...09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool Page 42 YES O W or...

Page 92: ...25008 Multi circuit tester set Tester knob indication Resistance 5 If OK then check the continuity between each terminal and ground PAIR valve resistance Infinity Terminal Ground Tester knob indicati...

Page 93: ...operation manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control 1 4 Click each button 2 At this time if an operation sound is heard from the PAIR control solenoi...

Page 94: ...IR control valve and PAIR bracket Page 14 Remove the exhaust pipes and mufflers 6 VL1500 Service Manual 3 5 Remove the heat shield bolt and fuel tank mounting bolts VL1500 Service Manual 5 2 Remove th...

Page 95: ...se attachment 09915 74511 Oil pressure gauge set Turn the ignition switch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm2 43 psi If the fuel pressure is lower than the specific...

Page 96: ...fuel pump may be faulty replace the fuel pump with a new one FUEL DISCHARGE AMOUNT INSPECTION Remove the seats Page 121 Remove the speedometer and fuel inlet cover VL1500 Service Manual 6 3 Remove th...

Page 97: ...9 US Imp oz 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pump relay is located at the right side of the ECM Remove the left frame head cover VL1500 Servi...

Page 98: ...e rear part A and turn the fuel pump mounting plate counterclockwise to approx 90 Pull out the fuel pump mounting plate until the fuel pressure regulator 7 comes out from the fuel tank Turn the fuel p...

Page 99: ...tank Set the fuel pump mounting plate to the horizontal line Turn the fuel pump mounting plate counterclockwise to approx 90 Pull the fuel pump mounting plate until the fuel pump band 9 comes out fro...

Page 100: ...VL1500K5 05 MODEL 99 FUEL PUMP DISASSEMBLY CONSTRUCTION 1 Band 4 Fuel pump holder 2 Fuel pump 5 O ring ITEM N m kgf m lb ft 3 Rubber cushion A Fuel pump mounting bolt A 10 1 0 7 0 SAMPLE...

Page 101: ...low smoothly and loss in engine power may result Blow the fuel mesh filter with compressed air NOTE If the fuel mesh filter is clogged with many sediment or rust replace the fuel filter cartridge with...

Page 102: ...assembly When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly and then to the specified torque in the ascending order of numbers Fuel pump mounting bo...

Page 103: ...pe A STP sensor mounting screw 4 Fuel delivery pipe joint hose B TP sensor mounting screw ITEM N m kgf m lb ft 5 Fuel injector C Fuel delivery pipe joint hose A 3 5 0 35 2 5 6 O ring mounting screw B...

Page 104: ...seats 1 Page 121 Remove the speedometer and fuel inlet cover 2 frame head covers 3 and frame upper covers 4 VL1500 Service Manual 6 3 Loosen the throttle body clamp screws Disconnect the IAT sensor co...

Page 105: ...coupler 2 Place a rag under the fuel feed hose and disconnect the fuel feed hose 3 from the delivery pipe Disconnect the fuel injector couplers Loosen the throttle body clamp screws at the intake pipe...

Page 106: ...nect the TP sensor coupler 4 and IAP sensor vacuum hoses 5 Remove the throttle body assembly THROTTLE BODY DISASSEMBLY Remove the fuel delivery pipe joint hose 1 Remove the fuel delivery pipes 2 Remov...

Page 107: ...a paint or scribe for accurate reinstallation Never remove the STVA 5 from the throttle body Never remove the secondary throttle valve 6 and throttle valve 7 Avoid removing the throttle valve adjuste...

Page 108: ...aking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions for proper use handling and storage Do not use wire to clean passageways Wire c...

Page 109: ...nch STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to page 110 for STP sensor setting proced...

Page 110: ...with the fuel injectors Tighten the fuel delivery pipe mounting screws to the speci fied torque Fuel delivery pipe mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft Apply thin coat of the engine oil to the...

Page 111: ...er of removal Pay attention to the following points Install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration STP SENSOR ADJUSTMENT If the STP sensor adjustme...

Page 112: ...rs Remove the fuel delivery pipe hose and pipes Page 105 Remove the fuel injectors 1 and 2 Page 105 FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination If presen...

Page 113: ...gine and run it in idling condition for warming up Connect a tachometer and set the idle rpm to 1 000 rpm by the throttle stop screw 1 Check and adjust the TP sensor Page 36 Turn the ignition switch O...

Page 114: ...age variation 0 064 0 096 V If the voltage variation is out of specification turn in or out the fast idle adjust screw 4 to adjust the voltage to specification Cool down the engine to ambient air temp...

Page 115: ...6 3 Start up the engine and run it in idling condition for warming up Stop the warmed up engine Disconnect the IAP sensor couplers 1 Disconnect the IAP sensor vacuum hoses 2 from each throt tle body C...

Page 116: ...air screw passageways NOTE Slowly turn the idle air screw in clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be res...

Page 117: ...the gauge so that the vacuum acting on the tube of that hose will bring the steel ball 5 in the tube to the center line 6 NOTE The vacuum gauge is positioned approx 45 from the horizontal level After...

Page 118: ...er than one ball turn the idle air screw on the throttle body and bring the ball to the same level A correctly adjusted throttle valve synchronization has the balls in the No 1 and No 2 at the same le...

Page 119: ...EMOVAL INSTALLATION Remove the right frame head cover and right frame upper cover VL1500 Service Manual 6 3 Remove the TP sensor and disconnect the coupler 1 09930 11950 Torx wrench Install the TP sen...

Page 120: ...r box Page 66 IAT SENSOR REMOVAL INSTALLATION Remove the right frame head cover and right frame upper cover VL1500 Service Manual 6 3 Disconnect the IAT sensor coupler 1 and remove the IAT sensor Inst...

Page 121: ...pre muffler Page 87 HO2 SENSOR REMOVAL INSTALLATION Remove the seats Page 121 Disconnect the coupler 1 and remove the HO2 sensor unit Installation is in the reverse order of removal Tighten the senso...

Page 122: ...er to the chapter 6 of Service Manual Remove the rear seat 1 Remove the seat bracket 2 and front seat 3 SEAT INSTALLATION Installation is in the reverse order of removal Pay attention the following po...

Page 123: ...Rebound Spring E Upper inner tube cover 5 Damper rod F Rubber 6 Inner tube G Washer 7 Slide metal H lower inner tube cover 8 Dust seal I Inner tube cover stopper ITEM N m kgf m lb ft 9 Oil seal stoppe...

Page 124: ...n the steering stem head nut 1 Loosen the front fork upper clamp bolts 2 left and right NOTE Slightly loosen the front fork cap bolts 3 before loosening the lower clamp bolts to facilitate later disas...

Page 125: ...ree length Service Limit 589 mm 23 2 in REASSEMBLY AND REMOUNTING The front fork reassembly and remounting procedures are differ ent from those of the VL1500K4 04 MODEL For details other than the foll...

Page 126: ...9 in A from the upper surface of the inner tube Set the washer 2 and rubber 3 to the inner tube Install the upper inner tube cover 4 NOTE When installing the front fork inner tube upper cover align th...

Page 127: ...ed torque Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the front fork cap bolt 6 to the specified torque Front fork cap bolt 23 N m 2 3 kgf m 16 5 lb ft Tighten the front fork upper...

Page 128: ...3 IAP sensor Front Page 49 A Oil pressure switch 4 Ignition coil 2 B EOT sensor Page 58 5 Horn Except for E 03 24 28 and 33 C IAT sensor Page 66 6 Automatic decompression relay D Speed sensor Page 14...

Page 129: ...For E 02 19 24 Page 87 3 STV actuator Page 74 A Ignition coil 1 4 IAP sensor Rear Page 49 B Regulator rectifier 5 ECM Engine Control Module C Generator 6 Fuel pump relay Page 96 D CKP sensor Page 47...

Page 130: ...esistance 0 1 1 0 White White White Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance NOTE When making above test it is not necessary to remove the gen erator GENERATOR NO...

Page 131: ...d value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test 0 B Black B R Black with Red B W Black with White tracer 1 4 V and more te...

Page 132: ...A Automatic decompression relay Automatic decom pression solenoid Starter relay Starter motor Starter button Clutch lever position switch IG switch Fuse 15A Turn signal side stand relay Engine stop sw...

Page 133: ...itch coupler to the wiring har ness Turn the ignition switch to ON position and side stand to upright position Insert the needle pointed probes to the gear position switch coupler Measure the voltage...

Page 134: ...p switch is in the RUN position Squeeze the clutch lever Check that the fuse is not blown and the battery is fully charged before diagnosing Step 1 1 Check the ignition system couplers for poor connec...

Page 135: ...oils Page 136 Are the ignition coils OK Step 6 1 Measure the CKP sensor peak voltage and its resistance Page 136 and 137 NOTE The CKP peak voltage inspection is applicable only with the multi circuit...

Page 136: ...e Black Yellow terminal Probe Ground NOTE Do not disconnect the ignition coil primary wire coupler 09900 25008 Multi circuit tester set Shift the transmission into neutral and turn ignition switch ON...

Page 137: ...ester knob indication Resistance CKP SENSOR PEAK VOLTAGE Remove the seats Page 121 Remove the speedometer and fuel inlet cover frame head covers and frame upper covers VL1500 Service Manual 6 3 NOTE M...

Page 138: ...the ECM coupler is out of specification the wire harness must be replaced If both peak voltages are out of specification the CKP sensor must be replaced and re checked CKP SENSOR RESISTANCE Remove the...

Page 139: ...CHEC But it is not a malfunction This condition implies that combination meter receives no signal from the ECM In that case they are restored to normal indication by turning the engine stop switch to...

Page 140: ...speedometer 1 Disassemble the speedometer as follows When disconnecting and reconnecting the speedome ter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged 1 Select...

Page 141: ...eplace the fuel level gauge with a new one FUEL LEVEL INDICATOR If the fuel level indicator A does not function properly check the fuel level gauge and its lead wire coupler If the fuel level gauge an...

Page 142: ...ing bolt Connect 12 V battery 10 k resistor and the multi circuit tester as shown in the right illustration R B Red with Black tracer B W Black with White tracer P Pink 09900 25008 Multi circuit teste...

Page 143: ...OFF ON Color Position O B O W OFF RUN Color Position IGNITION SWITCH HAZARD OIL PRESSURE SWITCH PASSING LIGHT SWITCH DIMMER SWITCH HORN BUTTON FRONT BRAKE SWITCH REAR BRAKE SWITCH CLUTCH LEVER POSITIO...

Page 144: ...BATTERY SPECIFICATIONS a Anode plates e Stopper b Separator fiberglass plate f Filter c Cathode plates g Terminal d Upper cover breather h Safety valve Type designation FTZ16 BS 1 Capacity 12 V 64 8...

Page 145: ...nsor Starter motor Ground wire Oil pressure switch 6 N m 0 6 kgf m 4 5 lb ft 6 N m 0 6 kgf m 4 5 lb ft 160 N m 16 0 kgf m 115 5 lb ft 14 N m 1 4 kgf m 10 0 lb ft Side stand switch Gear position switch...

Page 146: ...r hose Set the clamp between the IAP sensor and horn bracket Clamp Decomp solenoid Wiring harness STVA Wiring harness Stop lamp switch Speed sensor Clamp Stop lamp switch Battery OIL pressure switch C...

Page 147: ...wire For E 03 24 28 33 Horn lead wire For E 02 19 Generator lead wire Put lead wire into the space Ignition switch IAP sensor Fuel pump relay ECM Battery Starter motor Clamp Horn Except for E 03 24 2...

Page 148: ...mm 1 57 in 160 mm 6 30 in Throttle cable No 1 Clutch hose Throttle cable No 2 Wiring harness Clutch hose Throttle cable No 1 Throttle cable No 2 Wiring harness Clamp Throttle cables and wiring harnes...

Page 149: ...stopper tighten the union bolt to the specified torque 4 Pass through the brake hose inside of the hose guide 2 After positioning the hose clamp with stopper tighten the clamp bolt 5 Bind the brake h...

Page 150: ...e union has contacted the stopper tighten the union bolt 5 After positioning the clamp with the stopper tighten the clamp bolt 2 Brake hose must be passed over the brake support boss and caliper brack...

Page 151: ...hose Rear cylinder 9 Air cleaner box ITEM N m kgf m lb ft 3 IAP sensor vacuum hose Front cylinder 0 IAT sensor 0 20 2 0 14 4 4 Purge hose E 33 only A IAP sensor Front cylinder C 22 2 2 16 0 5 Surge h...

Page 152: ...10 N m 1 0 kgf m 7 0 lb ft 5 N m 0 5 kgf m 3 7 lb ft The ends of the clamp should face right side The ends of the clamp should face left side Water drain hose Fuel feed hose The ends of the clamp sho...

Page 153: ...with PAIR reed valve 1 Connect the air hose to the air cleaner box 2 Cushion seat Apply an adhesive agent to the cushion seat 2 Matching mark Yellow 3 Wiring harness 3 Matching mark White 1 2 3 20 40...

Page 154: ...FUEL INLET COVER INSTALLATION USA Others USA Others 1 2 1 Frame upper cover L 5 Fuel lid hinge bracket 2 Frame upper cover R 6 Fuel lid 3 Speedometer Fuel inlet cover 7 Fuel lid cover 4 Speedometer s...

Page 155: ...154 VL1500K5 05 MODEL FRAME UPPER COVER INSTALLATION 1 Cushion seat 4 Molding 2 Apply an adhesive agent 5 Bend up the stay 3 Cushion rubber 6 50 mm 2 0 in SAMPLE...

Page 156: ...VL1500K5 05 MODEL 155 FRAME HEAD COVER INSTALLATION 1 Cushion seat 3 3 mm 0 12 in 2 Apply an adhesive agent SAMPLE...

Page 157: ...156 VL1500K5 05 MODEL GREASE UP POINTS BRAKE PEDAL INSTALLATION 50 N m 5 0 kgf m 36 0 lb ft H H Brake pedal height 98 mm 3 86 in Apply an adhesive agent SAMPLE...

Page 158: ...ot 09900 25009 Needle pointed probe set 09900 28630 TPS test wire har ness 09904 41010 SDS set tool 99565 01010 004 CD ROM Ver 4 09915 74511 Oil pressure gauge 09940 40211 Fuel pressure gauge adapter...

Page 159: ...r 22 2 2 16 0 Fuel pump mounting bolt 10 1 0 7 0 STPS mounting screw 3 5 0 35 2 5 TPS mounting screw 3 5 0 35 2 5 Fuel delivery pipe mounting screw 5 0 5 3 5 Fuel delivery pipe hose mounting screw 5 0...

Page 160: ...0 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN 2 5 0 10 EX 2 2 0 09 Valve seat width IN 0 9 1 1 0 035 0 043 EX 1 0 1 2 0 039 0 047 Valv...

Page 161: ...0 9835 Camshaft runout Front Rear 0 10 0 004 Rocker arm I D IN 14 000 14 018 0 5511 0 5519 EX 16 000 16 018 0 6299 0 6303 Rocker arm shaft O D IN 13 966 13 984 0 5498 0 5506 EX 15 966 15 984 0 6286 0...

Page 162: ...992 23 000 0 9052 0 9055 22 980 0 9047 ITEM STANDARD LIMIT Conrod small end I D 23 015 23 023 0 9061 0 9064 23 040 0 9071 Conrod big end side clearance 0 10 0 20 0 004 0 008 0 3 0 012 Conrod big end...

Page 163: ...ch master cylinder piston diam 13 957 13 984 0 5495 0 5506 Clutch release cylinder bore 33 600 33 662 1 3228 1 3253 Clutch release cylinder piston diam 33 550 33 575 1 3209 1 3218 ITEM STANDARD LIMIT...

Page 164: ...V EOT sensor input voltage 4 5 5 5 V EOT sensor output voltage 0 1 4 6 V EOT sensor resistance Approx 61 3 k at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 1 4 6 V IAT sen...

Page 165: ...esistance Primary 1 7 Terminal Terminal Secondary 18 28 k Plug cap Terminal Ignition coil primary peak voltage Front 180 V and more B Y Ground Rear 180 V and more W Ground Generator coil resistance 0...

Page 166: ...pedal height 98 3 86 Brake disc thickness Front 4 8 5 2 0 189 0 205 4 5 0 18 Rear 6 6 7 0 0 260 0 276 6 3 0 25 Brake disc runout 0 30 0 012 Master cylinder bore Front 15 870 15 913 0 6248 0 6265 Rear...

Page 167: ...T 200 2 00 29 200 2 00 29 REAR 250 2 50 36 250 2 50 36 ITEM SPECIFICATION LIMIT Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research met...

Page 168: ...TEM STANDARD LIMIT Front fork oil capacity each leg 416 ml 14 1 14 6 US lmp oz Bevel gear oil type Hypoid Gear oil 90 API GL 5 Bevel gear oil capacity Final 200 220 ml 6 8 7 0 7 4 7 7 US lmp oz Brake...

Page 169: ...his fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits 1 Fuel tank 7 Fuel mesh filter For low pressure 2 Fuel filter For high pressure...

Page 170: ...CV system Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body 1 PAIR control solen...

Page 171: ...drawn into the exhaust port through the PAIR solenoid valve and PAIR reed valve The PAIR solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS EOTS IATS IAPS...

Page 172: ...or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Re...

Page 173: ...2 Inspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one Install the reed valve A and its case B with outlet pipes C...

Page 174: ...of the PAIR con trol solenoid valve Resistance 20 24 at 20 30 C 68 86 F 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is not within the standard range replac...

Page 175: ...5 MODEL PAIR AIR SUPPLY SYSTEM DIAGRAM 1 2 3 A FRESH AIR 4 No 2 cylinder B EXHAUST GAS 1 From air cleaner 1 PAIR control solenoid valve 2 To No 1 cylinder 2 PAIR reed valve 3 To No 2 cylinder 3 No 1 c...

Page 176: ...0 40 mm 0 79 1 57 in 15 20 mm 0 59 0 79 in 15 20 mm 0 59 0 79 in 1 PAIR control solenoid valve with PAIR reed valve 1 Connect the air hose to the air cleaner box 2 Cushion seat Apply adhesive agent to...

Page 177: ...4 F White White 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is not within the standard range replace the HO2 sensor with a new one NOTE Temperature of the...

Page 178: ...Br Gr W Y R Gr B Y R Gr W Y R Gr B Y R Dg B Br Dg B Br B Bl B Br B Y B Bl B Br B Y B Br G B R B Br G B R B Br G W R B Br G W R Br G Y B B B Br G Y B B B B B B R R B W B W B B B R R B W B W O W Br B O...

Page 179: ...B Y G B Y Gr B Gr W B W P W W B B Lg Bl R Bl Y Gr R B G W R G Y Bl Y G B Br B Br G B Bl B Br W B Bl O Y Bl W Bl B Bl G B Br B W R W O G Y R Br Y B W G R Y W G W Dg R B B Br Bl W Bl B Bl G Bl R Bl Y R...

Page 180: ...Prepared by May 2004 Part No 99501 39550 01E Printed in Japan 176 SAMPLE...

Page 181: ...Printed in Japan K5...

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