Suzuki 2010 VZ800L0 Supplementary Service Manual Download Page 2 | Manualshive

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VZ800L0 (’10-MODEL) 1

CONTENTS

VZ800L0 (’10-MODEL)

© COPYRIGHT SUZUKI MOTOR CORPORATION 2009

This manual describes service specifications, service data and servicing procedures which dif-
fer from those of the VZ800K9 (’09-model).

NOTE:

• Any differences between the VZ800K9 (’09-model) and VZ800L0 (’10-model) in specifi-

cations and service data are indicated with an asterisk mark (*).

• Please refer to the VZ800K9 (’09-model) service manual for details which are not given

in this manual.

INFORMATION LABELS ..................................................................................... 3
SPECIFICATIONS ................................................................................................ 4
SENSOR ............................................................................................................... 5

HO2 SENSOR INSPECTION ...................................................................... 5
HO2 SENSOR REMOVAL/INSTALLATION ............................................... 5

EXTERIOR PARTS............................................................................................... 6

REMOVAL ................................................................................................... 6
REMOUNTING ............................................................................................ 7

FRONT FORK....................................................................................................... 8

REMOVAL AND DISASSEMBLY ............................................................... 8
INSPECTION ............................................................................................. 11
REASSEMBLY AND REMOUNTING........................................................ 12

IGNITION SYSTEM ............................................................................................ 16

IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION ................... 16

SPEEDOMETER AND PILOT LAMP BOX ........................................................ 17

DESCRIPTION .......................................................................................... 17
SPEEDOMETER/HEADLIGHT COVER BRACE
REMOVAL AND DISASSEMBLY ............................................................. 18

LAMPS................................................................................................................ 21

HEADLIGHT, BRAKE/TAIL LIGHT,
LICENSE PLATE LIGHT AND TURN SIGNAL LIGHT............................. 21

WIRING HARNESS ROUTING........................................................................... 23
CABLE ROUTING .............................................................................................. 25
FRONT BRAKE ROUTING ................................................................................ 26
SPEED SENSOR HARNESS ROUTING............................................................ 27

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Summary of Contents for 2010 VZ800L0

Page 1: ......

Page 2: ...ls which are not given in this manual INFORMATION LABELS 3 SPECIFICATIONS 4 SENSOR 5 HO2 SENSOR INSPECTION 5 HO2 SENSOR REMOVAL INSTALLATION 5 EXTERIOR PARTS 6 REMOVAL 6 REMOUNTING 7 FRONT FORK 8 REMO...

Page 3: ...56A A2100001 JS1B4111100109993 JS1B4111300101636 JS1VS56A A2100001 JS1VS56A A2100001 VZ800UE E 19 E U JS1B4211100100232 HEAD LIGHT INSTALLATION 28 REAR COMBINATION LAMP INSTALLATION 29 FRAME HEAD COVE...

Page 4: ...VZ800L0 10 MODEL 3 INFORMATION LABELS A Attached VZ800L0 1 Tire information label A Except for E 03 33 For E 03 33...

Page 5: ...l 105 mm 4 1 in Caster 33 15 Trail 141 mm 5 6 in Steering angle 38 right left Turning radius 3 0 m 9 8 ft Front brake Disc brake Rear brake Drum brake Front tire size 130 90 16 M C 67H tubeless Rear t...

Page 6: ...ON The heated oxygen sensors are installed on the front exhaust pipe and rear muffler VZ800K9 32 to 35 NOTE Difference between L0 MODEL and K9 MODEL is addition of HO2 sensor to E 03 28 HO2 SENSOR REM...

Page 7: ...2 Remove the rear seat 3 by removing the bolts FRAME COVER Remove the left frame cover 1 with the ignition key Hooked part Remove the right frame covers 2 by removing the bolts Hooked part Wait until...

Page 8: ...ts apply a small quantity of THREAD LOCK to its mounting bolts and tighten them to the specified torque After temporary tightening tighten the bolts to the specified torque in order of A B C Page 35 9...

Page 9: ...52 Remove the front fender Loosen the front fork upper clamp bolt 1 NOTE Slightly loosen the front fork cap bolt 2 before loosening the lower clamp bolt to facilitate later disassembly Loosen the fron...

Page 10: ...cer holder A 09940 94922 Front fork spring stopper plate B Remove the front fork cap bolt from the inner rod by loosening the lock nut Compress the fork spring with the special tool and remove the spe...

Page 11: ...rewdriver into the gap B between inner tube and damper rod to prevent the damper rod from rotating Remove the inner rod damper rod cartridge 6 Extract the outer tube from the inner tube NOTE Be carefu...

Page 12: ...r tube inner sur face for scratches Inspect the ANTI FRICTION metal surfaces for scratches If any defects are found replace them with a new one FORK SPRING Measure the fork spring free length If it is...

Page 13: ...eal and oil seal retainer onto the inner tube 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer Insert the inner tube into the outer tube and fit the oil seal and dust seal with the s...

Page 14: ...Damper rod bolt 23 N m 2 3 kgf m 16 5 lbf ft FORK OIL Place the front fork vertically without spring Compress it fully Pour specified front fork oil up to the top level of the outer tube Capacity eac...

Page 15: ...djust fork oil level with the special tool NOTE When adjusting the fork oil level compress the outer tube fully without the fork spring Fork oil level 153 mm 6 02 in 09943 74111 Front fork oil level g...

Page 16: ...gn the upper surface of the outer tube with the upper sur face of the steering stem upper bracket and tighten the front fork lower clamp bolt 3 to the specified torque Front fork lower clamp bolt 3 33...

Page 17: ...16 VZ800L0 10 MODEL IGNITION SYSTEM IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION VZ800K9 Page 56 NOTE Difference between L0 MODEL and K9 MODEL is addition of twin spark plug to E 03 28...

Page 18: ...ays CHEC But it is not a malfunction This condition implies that speedometer receives no signal from the ECM In that case they are restored to normal indication by turning the engine stop switch to RU...

Page 19: ...BLY Disconnect the headlight coupler 1 Remove the headlight Page 28 Disconnect the speedometer lead wire coupler Remove the speedometer When disconnecting and reconnecting the speedome ter coupler mak...

Page 20: ...VZ800L0 10 MODEL 19 Disconnect the clamps 2 Disconnect the speed sensor coupler 3 handlebar switch couplers 4 and front turn signal light couplers 5 Remove the headlamp brace 6...

Page 21: ...0 VZ800L0 10 MODEL Disassemble the speedometer as follows Do not attempt to disassemble the speedometer unit 1 Upper cover 3 Speedometer 5 Pilot lamp box assembly 2 Upper case assembly 4 Lower case FW...

Page 22: ...POSITION LIGHT 12 V 5 W E 02 19 24 BRAKE TAIL LIGHT LED LICENCE PLATE LIGHT 12 V 5 W TURN SIGNAL LIGHT Front 12 V 21 5 W E 03 28 33 12 V 21 W E 02 19 24 Rear 12 V 21 W FWD FWD FWD If you have touched...

Page 23: ...VZ800L0 10 MODEL HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam A Vertical adjuster B Horizontal adjuster NOTE To adjust the headlight beam adjust the beam horizontally first then adjust vertical...

Page 24: ...o not pass the high tension cable over the bracket 13 No clearance 7 Do not pinch the wiring harness with PAIR pipe and water hose 14 Do not pinch the lead wires between the cover and fender boss when...

Page 25: ...inch the fuel tank coupler between the main wire harness and fuel tank when installing the fuel tank 5 Pass the lead wires under the frame Do not contact the lead wires with fuel tank To brake switch...

Page 26: ...ss end of the clamp inside of the seat rail 4 Clamp in this direction 9 Adjust the clutch cable play using the engine side adjuster with the thread part of lever side adjuster 3 5 mm 0 19 0 20 in left...

Page 27: ...union touching to the stopper tighten the union bolt 3 Clamp the sleeve firmly 4 Set the clamp with stopper before tightening 2 Pass the brake hose outside of the guide 5 Pass the brake hose outside o...

Page 28: ...ess in front of the brake hose and guide 2 Clip 2 Pass the speed sensor harness in front of the brake hose guide 3 Yellow mark 3 Do not catch the speed sensor harness to the caliper boss 4 Guide 4 Con...

Page 29: ...28 VZ800L0 10 MODEL HEAD LIGHT INSTALLATION 1 Head lamp cover 4 Left turn signal lamp 2 Head lamp 5 Right turn signal lamp 3 Head lamp brace 6 Front turn signal lamp cover VIEW A A...

Page 30: ...STALLATION 1 Rear combination lamp 5 Right turn signal lamp 2 License lamp 6 Left turn signal lamp 3 License plate bracket 7 Rear fender extension 4 Reflex reflector 5 N m 0 5 kgf m 3 6 lbf ft 1 8 N m...

Page 31: ...FRAME HEAD COVER CUSHION INSTALLATION LEFT SIDE COVER CUSHION INSTALLATION 1 Cushion 4 5 mm 0 20 in 7 10 mm 0 39 in 2 3 mm 0 12 in 5 15 mm 0 59 in 3 12 mm 0 47 in 6 20 mm 0 79 in 1 Cushion 2 25 mm 1 0...

Page 32: ...ness Rear combination lamp harness Rear fender Clamp Pipe Pipe License plate cushion For E 03 28 33 Fender brace cushion 20 30 mm 0 8 1 2 in 10 20 mm 0 4 0 8 in 50 60 mm 2 0 2 4 in 10 mm 0 4 in Rear c...

Page 33: ...n coil 2 sub 5 Protector A Ignition coil bolt 1 When installing the rear ignition coil bracket temporarily tighten the bolts a and b first 2 Pass the spacer to the hole c of protector securely Do not...

Page 34: ...age box Clamp Seat lock cable Luggage box 1 1 2 Rear frame Rear frame Frame Rear fender Rear fender Seat lock cable Rear fender Frame A C B VIEW B VIEW C VIEW A 1 Set the seat lock cable firmly Do not...

Page 35: ...34 VZ800L0 10 MODEL REAR FENDER INSTALLATION 23 N m 2 3 kgf m 16 5 lbf ft Rear fender extention Rear frame Rear fender brace Rear front fender Rear fender...

Page 36: ...0 10 MODEL 35 REAR FRAME INSTALLATION 50 N m 5 0 kgf m 36 lbf ft 50 N m 5 0 kgf m 36 0 lbf ft 1 Frame Rear frame 1 1 1 After temporary tightening tighten the bolts to the specified torque in order of...

Page 37: ...Clutch cable adjuster lock nut engine side 4 5 0 45 3 5 ITEM N m kgf m lbf ft Front fork damper rod bolt 23 2 3 16 5 Rear frame mounting bolt 50 5 0 36 0 Rear fender brace bolt 23 2 3 16 5 License la...

Page 38: ...coolant temp warning light LED Turn signal indicator light LED High beam indicator light LED Neutral indicator light LED Oil pressure indicator light LED FI indicator light LED ITEM STANDARD LIMIT Fro...

Page 39: ...W B R O W B Bl O W B R O B O W B R B Bl Y G Y B Y G Y W O Y B Y G Y W O O B O W B R B Bl Y G O B O W O G W B Y G O B O W O G W B Y G O W W O W W O W B Y O W B Y B Br Bl B R O G W B O G W B O G W B B...

Page 40: ...O O B O W B R B Bl Y G O B O W O G W B Y G O B O W O G W B Y G O W W O W W O W B Y O W B Y B Br Bl B R O G W B O G W B O G W B B W O G B Y Y Bl B Lg B B W O G B Y Y Bl B Lg B B W O G Y B Y Bl Lg B B...

Page 41: ...Prepared by August 2009 Part No 99501 38110 01E Printed in Japan 40...

Page 42: ......

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