Suzuki Intruder VL1500B Manual Download Page 2

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IMPORTANT



WARNING/



CAUTION/

NOTICE

/NOTE

Please read this manual and follow its
instructions carefully. To emphasize
special information, the symbol



and

the words

WARNING

CAUTION

NOTICE

and

NOTE

have special mean-

ings. Pay particular attention to mes-
sages highlighted by these signal
words:

NOTE: Indicates special information to
make maintenance easier or instruc-
tions clearer.



WARNING

Indicates a potential hazard that
could result in death or serious
injury.



CAUTION

Indicates a potential hazard that
could result in minor or moderate
injury.

NOTICE

Indicates a potential hazard that
could result in vehicle or equipment
damage.

Summary of Contents for Intruder VL1500B

Page 1: ...t as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehi...

Page 2: ...s Pay particular attention to mes sages highlighted by these signal words NOTE Indicates special information to make maintenance easier or instruc tions clearer WARNING Indicates a potential hazard th...

Page 3: ...engine components is necessary for this motorcycle to comply with the EPA and CARB regulations Therefore please follow the maintenance instructions closely to ensure emission compliance Your authoriz...

Page 4: ...s in conservation and protection of Earth s Natural resources To that end we encourage every vehicle owner to recy cle trade in or properly dispose of as appropriate used motor oil engine coolant and...

Page 5: ......

Page 6: ...ND COOLANT RECOMMENDATIONS CONTROLS EQUIPMENT AND ADJUSTMENTS BREAK IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE...

Page 7: ......

Page 8: ...HING 1 4 SPECIAL SITUATIONS REQUIRE SPECIAL CARE 1 5 KNOW YOUR LIMITS 1 5 BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS 1 6 PRACTICE AWAY FROM TRAFFIC 1 7 INSPECTION BEFORE RIDING 1 7 ACCESSORIES AND...

Page 9: ...motorcyclist or how experi enced you are you will eventually face some challenging situations In preparing for these challenges you will be fine tuning your coordination concentration and attitude Le...

Page 10: ...d other motorists the best view of you Wear bright reflective clothing Put reflective strips on your helmet IF YOU DON T HAVE A HELMET BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE Most accidents occur...

Page 11: ...of fingers over the lever when riding in traffic and near intersec tions to give their reaction time a head start Emergency stopping and swerving are techniques that you should practice and master be...

Page 12: ...ver braking when traction is limited will cause your tires to skid pos sibly resulting in loss of directional con trol or causing you and your motorcycle to fall over KNOW YOUR LIMITS Always ride with...

Page 13: ...or under the influence of alcohol or other drugs PLEASE DO NOT RIDE your motorcy cle BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days especially wet ones requires extra caution...

Page 14: ...he MSF s Rider Courses Even experts will be pleased with the caliber of the infor mation presented in these courses As the MSF says The more you know the better it gets INSPECTION BEFORE RIDING Review...

Page 15: ...great way to share the joy of motorcycling You will have to alter your riding style somewhat since the extra weight of a passenger will affect han dling and braking You may also need to adjust tire p...

Page 16: ...s This manual can increase 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...

Page 17: ...by wearing a helmet and other protective gear and learning emergency braking and swerv ing techniques to minimize the damage to you and your machine The best way to learn basic riding skills and evasi...

Page 18: ...2 1 2 FUEL OIL AND COOLANT RECOMMENDATIONS FUEL 2 2 ENGINE OIL 2 5 FINAL GEAR OIL 2 8 ENGINE COOLANT SOLUTION 2 8...

Page 19: ...due to the fuel the motorcycle uses In such case try changing to a different gas station If the situation is not improved by changing consult your Suzuki dealer If pinking or knocking is experi enced...

Page 20: ...an those recom mended for gasoline Fuel Pump Labeling In some states pumps that dispense oxygenated fuels are required to be labeled for the type and percentage of oxygenate and whether important addi...

Page 21: ...u are not satisfied with the driv ability of your motorcycle when you are using an oxygenated fuel or if engine pinging is experienced sub stitute another brand as there are differences between brands...

Page 22: ...ways select good quality engine oil Use oil with an API American Petroleum Insti tute classification of SG SH SJ SL SM or SN with a JASO classification of MA API American Petroleum Institute JASO Japa...

Page 23: ...standard is an index to select engine oils for 4 stroke motorcy cle and ATV engines Motorcycle and ATV engines lubricate clutch and trans mission gears with engine oil JASO T903 specifies performance...

Page 24: ...have an ENERGY CONSERVING or RESOURCE CONSERVING indica tion in the API classification donut mark These oils can affect engine life and clutch performance API SG SH SJ SL SM or SN Recommended API SH...

Page 25: ...t temperature is below 0 C 32 F use SAE80 hypoid gear oil ENGINE COOLANT SOLUTION Use SUZUKI SUPER LONG LIFE COOLANT or SUZUKI LONG LIFE COOLANT If SUZUKI SUPER LONG LIFE COOLANT and SUZUKI LONG LIFE...

Page 26: ...antifreeze or coolant solution If swallowed do not induce vomiting Immediately contact a poi son control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coola...

Page 27: ...used at all times even though the atmospheric temperature in your area does not go down to the freezing point SUZUKI SUPER LONG LIFE COOLANT Blue SUZUKI SUPER LONG LIFE COOL ANT is pre mixed to the p...

Page 28: ...solution capacity total 2650 ml 2 8 US qt NOTE This 50 mixture will protect the cooling system from freezing at temper atures above 31 C 24 F If the motorcycle is to be exposed to tempera ture below...

Page 29: ......

Page 30: ...TION OF PARTS 3 2 KEY 3 5 IGNITION SWITCH 3 5 STEERING LOCK 3 7 INSTRUMENT PANEL 3 8 LEFT HANDLEBAR 3 18 RIGHT HANDLEBAR 3 21 FUEL TANK CAP 3 26 GEARSHIFT LEVER 3 28 REAR BRAKE PEDAL 3 30 HELMET HOLDE...

Page 31: ...T AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Front brake lever 8 Fuel tank...

Page 32: ...ols C Battery and Main fuse D Helmet holder E Sidecase VL1500T F Gearshift lever G Engine oil filter H Footrests I Engine oil filler cap J Side stand K Engine oil drain plug L Speed sensor M Engine co...

Page 33: ...3 4 O Fuses P Rear brake fluid reservoir Q Steering lock R Rear brake light switch S Rear brake pedal VL1500B VL1500T...

Page 34: ...ys come with this motorcycle Keep the spare key in a safe place IGNITION SWITCH The ignition switch has 3 positions OFF position All electrical circuits are cut off The engine will not start The key c...

Page 35: ...ion The taillight will come on to increase visibility for temporary road side parking at night Push down the key and turn it to the P position The key can be removed WARNING If the motorcycle falls do...

Page 36: ...into the steer ing lock and turn it counterclockwise to lock the steering WARNING Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could...

Page 37: ...tch 2 Hold the button 9 for 3 seconds NOTE The reset procedure from step 1 to step 2 should be performed within 10 seconds TURN SIGNAL INDICATOR LIGHT 2 When the turn signals are being oper ated eithe...

Page 38: ...l pressure indi cator light has turned off before operating the throttle or running the motorcycle NOTICE Riding the motorcycle with the oil pressure indicator light lit can dam age the engine and tra...

Page 39: ...ates more than 120 C 248 F When the engine coolant temperature indicator light comes on stop the engine and check the coolant level after engine cools FI E F A B GEAR NOTICE Riding the motorcycle with...

Page 40: ...nd remains lit B The display 7 in the odometer dis play area indicates FI continuously and the red indicator light 6 blinks while cranking the engine The engine may continue to run in mode A but the e...

Page 41: ...3 12 NOTE If the display indicates FI con tinuously and the red indicator light blinks the engine will not start FI E F A B GEAR...

Page 42: ...gnition fuse and the connection of the lead wire couplers COMBINATION SYSTEM DISPLAY 7 The display has six functions clock odometer two trip meters instrument panel light brightness and gear position...

Page 43: ...3 14 To change the display push the button 8 The display changes in the order below FI E F A B GEAR GEAR A GEAR B GEAR GEAR Odometer Trip meter A Trip meter B Instrument panel light brightness...

Page 44: ...When the button 9 is held in the display advances continuously 3 Push the button 8 to highlight the minute display 4 Adjust the minute display by pushing the button 9 5 Push the button 8 to return to...

Page 45: ...ds of distances at the same time For instance trip meter A can register the trip distance and trip meter B can regis ter the distance between fuel stops To reset a trip meter to zero push the button 9...

Page 46: ...ator does not indi cate a number but indicates FUEL LEVEL INDICATOR 0 The fuel level indicator indicates the amount of fuel remaining in the fuel tank The fuel level indicator displays all 5 segments...

Page 47: ...eam is turned on LEFT HANDLEBAR Clutch Lever 1 The clutch lever is used for disengaging the drive to the rear wheel when start ing the engine or shifting transmission gears Squeezing the lever disenga...

Page 48: ...adlight Use the dimmer switch to select only the or position NOTICE Sticking tape or placing objects in front of the headlight can obstruct headlight heat radiation This can result in headlight damage...

Page 49: ...flash intermittently To cancel turn signal operation push the switch in WARNING Failure to use the turn signals and failure to turn off the turn signals can be hazardous Other drivers may misjudge you...

Page 50: ...is turned on with the ignition switch in the ON or P position Use the hazard warning lights to warn other traffic during emergency parking or when your vehicle could otherwise become a traffic hazard...

Page 51: ...3 22 Front Brake Lever 2 Apply the front brake by squeezing the front brake lever toward the grip The brake light will come on when the lever is squeezed Front Brake Lever Adjustment...

Page 52: ...position a projection of the brake lever pivot should fit into the depression of the adjuster This motorcycle is deliv ered from the factory with its adjuster set on position 3 WARNING Adjusting the...

Page 53: ...lever and push the electric starter switch to start the engine NOTE This motorcycle has a starter interlock system for the ignition and starter circuit The engine can only be started if The transmiss...

Page 54: ...in this manual NOTICE If the neutral indicator light and the gear position indicator are not giving proper indications starting the engine can cause serious engine damage Before starting the engine ma...

Page 55: ...ou to increase engine speed Turn it away from you to decrease engine speed FUEL TANK CAP To open the fuel tank cap insert the ignition key into the lock and turn it clockwise With the key inserted lif...

Page 56: ...ter the fuel tank when refueling NOTE Place the motorcycle on the side stand to fill up the fuel tank to specified 18 0 L 4 8 US gal 1 Fuel level 2 Filler neck WARNING If you overfill the fuel tank fu...

Page 57: ...or cause you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid spill ing fuel on a hot engine Do not smoke and make sure there are no open flames or sparks...

Page 58: ...gearshift lever to upshift Depress the front end of the gearshift lever to downshift Neutral is located between 1st and 2nd gear When neutral is desired depress or lift the lever halfway between 1st...

Page 59: ...3 30 REAR BRAKE PEDAL Pressing the rear brake pedal will apply the rear brake The brake light will come on when the rear brake is operated HELMET HOLDER VL1500B VL1500T...

Page 60: ...ing to the latch and turn the key back to lock the holder VL1500T NOTE The tool box is equipped with the helmet holder wire Open the tool box by referring to the TOOLS section WARNING Riding with a he...

Page 61: ...e ignition circuit when the side stand is down and the transmission is in any gear other than neutral The side stand ignition interlock sys tem works as follows If the side stand is down and the trans...

Page 62: ...iding Always retract the side stand completely before starting off NOTICE If you do not take proper precautions when parking the motorcycle can fall over Park the motorcycle on firm level ground whene...

Page 63: ...lock or unlock the side case lid with a spare key without a key cover use a key with a key cover If the lock is frozen pour warm water around the lock to melt the ice To close the sidecase Close the...

Page 64: ...ot keep valuable items in the sidecase when leaving the motorcy cle unattended Put articles in a waterproof bag when keeping the articles in the sidecase because the sidecase can get wet with rain or...

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Page 66: ...4 1 4 BREAK IN AND INSPECTION BEFORE RIDING BREAK IN 4 2 INSPECTION BEFORE RIDING 4 5...

Page 67: ...e Opening Recommendation The table below shows the maximum throttle opening recommendation dur ing the break in period Vary the Engine Speed Vary the engine speed during the break in period This allow...

Page 68: ...miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles WARNING Failure to perform break in of the tires could cause tire sli...

Page 69: ...will receive During break in operation all of the engine components will have mated together and seated Maintenance required as part of the initial service includes cor rection of all adjustments tigh...

Page 70: ...e it is in safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this owner s manual WARNING If you operate this motorcycle with improper tires or improper or uneven tire pressur...

Page 71: ...r clothing get caught in moving engine parts Shut the engine off when performing maintenance checks except when checking the lights engine stop switch and throttle WHAT TO CHECK CHECK FOR Steering Smo...

Page 72: ...38 Proper play Smooth response Quick return to idle position Gearshift lever 3 28 No damage Smooth operation Clutch 7 42 Smooth and progressive action Proper lever play Side stand ignition interlock...

Page 73: ......

Page 74: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF AND SHIFTING 5 5 USING THE TRANSMISSION 5 7 RIDING ON HILLS 5 9 STOPPING AND PARKING 5 10 CARRYING A PASSENGER 5 12...

Page 75: ...interlock system for the ignition circuit and the starter circuit The engine can only be started if The transmission is in neutral and the clutch is disengaged or The transmission is in gear the side...

Page 76: ...eutral indicator light and the gear position indicator are not giving proper indications starting the engine can cause serious engine damage Before starting the engine make sure of the followings When...

Page 77: ...ess Breathing carbon monoxide can cause death or severe injury Never start the engine or let it run indoors or where there is little or no ventilation NOTICE After starting the engine opening the thro...

Page 78: ...engine components and discoloration of exhaust pipes Shut the engine off if you cannot begin your ride promptly WARNING Riding at excessive speeds increases your chances of losing control of the motor...

Page 79: ...oot or leg may come in contact with the rear wheel This could injure you or cause an acci dent Always keep both hands on the han dlebars and both feet on the foot rests of your motorcycle during opera...

Page 80: ...lever as you open the throttle again Select higher gears in this manner until top gear is reached NOTE This motorcycle has a side stand ignition interlock system If you shift the transmission into ge...

Page 81: ...2nd 3rd 19 30 3rd 4th 25 40 4th 5th 31 50 Gear position mph km h 5th 4th 25 40 4th 3rd 19 30 WARNING Downshifting when engine speed is too high can cause the rear wheel to skid and lose traction due t...

Page 82: ...momentum When riding down a steep hill the engine may be used for braking by shifting to a lower gear Be careful however not to allow the engine to overrev WARNING Downshifting while the motorcycle is...

Page 83: ...sition when the motorcy cle is almost completely stopped The neutral position can be con firmed by observing the neutral indi cator light WARNING Inexperienced riders tend to underutilize the front br...

Page 84: ...wheel skid and loss of control Brake lightly and with care on slip pery or irregular surfaces WARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stopping...

Page 85: ...section and the Sus pension section of this manual The passenger should always hold onto your waist or hips or onto the seat strap or grab bar as equipped Ask your pas senger not to make any sudden m...

Page 86: ...5 13 To help prevent burn injuries warn your passenger not to contact the muffler when mounting or dismounting your motorcycle...

Page 87: ......

Page 88: ...6 1 6 ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE 6 2 ACCESSORY INSTALLATION GUIDELINES 6 3 LOADING LIMIT 6 4 LOADING GUIDELINES 6 5 MODIFICATION 6 7...

Page 89: ...nstalling the accessories on your motorcycle and consult your Suzuki dealer if you have any questions WARNING Improper installation of accessories or modification of the motorcycle may cause changes i...

Page 90: ...with the operation of the suspension steer ing or other control operations Accessories fitted to the handlebars or the front fork area can create seri ous stability problems The extra weight will caus...

Page 91: ...us situation due to the loss of electrical power during the opera tion of the motorcycle Do not pull a trailer or sidecar This motorcycle is not designed to pull a trailer or sidecar LOADING LIMIT WAR...

Page 92: ...ld Front 225 kPa 2 25 kgf cm2 33 psi Rear 280 kPa 2 80 kgf cm2 41 psi LOADING GUIDELINES This motorcycle is primarily intended to carry small items when you are not riding with a passenger Follow the...

Page 93: ...ability to balance and steer the motorcycle You should ride at reduced speeds less than 130 km h 80 mph when you are carrying cargo or have added accessories Adjust suspension setting as neces sary W...

Page 94: ...s including without limita tion modifications of any emission related parts such as the carburetor s fuel injection system components the engine control module air suction sys tem components the catal...

Page 95: ......

Page 96: ...ENGINE OIL 7 29 THROTTLE CABLE ADJUSTMENT 7 38 ENGINE IDLE SPEED INSPECTION 7 39 FUEL HOSE 7 40 CLUTCH ADJUSTMENT 7 42 ENGINE COOLANT 7 44 FINAL GEAR OIL 7 46 BRAKES 7 48 TIRES 7 56 SIDE STAND IGNITIO...

Page 97: ...eriodic services in kilometers miles and months are shown At the end of each interval be sure to perform the maintenance listed MAINTENANCE REPLACEMENT OR REPAIR OF THE EMISSION CONTROL DEVICES AND SY...

Page 98: ...rked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs ask your Suzuki dealer to do the maintenance WAR...

Page 99: ...a qualified mechanic NOTICE Servicing electric parts with the igni tion switch in the ON position can damage the electric parts when the electric circuit is shorted Turn off the ignition switch befor...

Page 100: ...er bolts T T T Valve clearance I I I Spark plugs 7 24 I R I R Fuel hose 7 40 I I I I Engine oil 7 29 R R R R R Engine oil filter 7 29 R R Throttle cable play 7 38 I I I I I PAIR air supply system I I...

Page 101: ...ths 2 12 24 36 48 km 1000 6000 12000 18000 24000 Item miles 600 4000 7500 11000 14500 Radiator hose 7 46 I I I I Final gear oil 7 46 R I I Clutch cable play 7 42 I I I I Brakes 7 48 I I I I I Brake ho...

Page 102: ...s provided with your motorcy cle The tool box is located on the left side of the motorcycle 1 Unhook the hooks and remove the cover 2 To open the tool box insert the igni tion key into the lock and tu...

Page 103: ...for your motorcycle Be sure that all lubri cation is performed during periodic maintenance on the motorcycle Increase frequency when you use your motorcycle in severe conditions Grease NOTICE Lubricat...

Page 104: ...battery is a sealed type battery and requires no maintenance The standard charging rate is 1 8A 5 to 10 hours and the maximum rate is 9 0A 1 hour WARNING Battery posts terminals and related accessori...

Page 105: ...if you suffer injury Keep batteries out of reach of children WARNING Batteries produce flammable hydro gen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the bat...

Page 106: ...e battery follow the proce dure below 1 Place the motorcycle on the side stand 2 Remove the bolt 1 NOTICE Exceeding the maximum charging rate for the battery can shorten its life Never exceed the maxi...

Page 107: ...7 12 3 Push down the front end of the rear seat 2 and pull the seat backward 4 Remove the bolts and seat band 3 To remove the front seat 4 raise the rear end of the front seat and slide it backward...

Page 108: ...stall the battery 1 Install the battery in the reverse order of removal 2 Connect the battery terminals securely NOTICE Reversing the battery lead wires can damage the charging system and the battery...

Page 109: ...ic substances including sulfuric acid and lead They could cause injury to humans or could damage the environment A used battery must be disposed of or recycled according to local law and must not be d...

Page 110: ...an 0 004 lead By ensuring the used battery is dis posed of or recycled correctly you will help prevent potential negative conse quences for the environment and human health which could otherwise be ca...

Page 111: ...nspect the air cleaner element much more frequently Use the following pro cedure to remove the element and inspect it WARNING Operating the engine without the air cleaner element in place can be haz a...

Page 112: ...uently if the vehicle is used in dusty wet or muddy conditions can damage your motorcycle The air cleaner element can become clogged under these conditions and engine damage may result Always inspect...

Page 113: ...7 18 RIGHT LEFT...

Page 114: ...7 19 2 Loosen the clamp bolt 3 Remove the bolts Unhook the hook 4 Remove the air cleaner case 1 with the joint tube RIGHT LEFT 5 Remove the screws Remove the air cleaner case 2...

Page 115: ...7 20 RIGHT LEFT 6 Remove the screws Remove the air cleaner element 3 7 Inspect the air cleaner element con dition Replace the air cleaner ele ment periodically...

Page 116: ...sealed NOTICE Compressed air can damage the air cleaner element Do not blow the air cleaner element with compressed air NOTICE A torn air cleaner element will allow dirt to enter the engine and can da...

Page 117: ...air cleaner box when cleaning the motorcycle Reinstall the fuel tank NOTE Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank NOTICE Failure to positi...

Page 118: ...Cleaner Drain Plug RIGHT LEFT Remove the plug and drain water and oil at the periodic maintenance interval The air cleaner drain plugs are located inside the air cleaner box and air cleaner left cham...

Page 119: ...sulator indicates that the engine may need adjustment or another plug type may be needed Consult your authorized Suzuki dealer or a qualified mechanic if your plug insulator is not a light brown color...

Page 120: ...to avoid jamming elec tronic parts Improper spark plug selec tion may cause electronic interference with your motorcycle s ignition system resulting in motorcycle performance problems Use only the rec...

Page 121: ...7 26 Spark Plug Removal 1 Place the motorcycle on the side stand FRONT REAR...

Page 122: ...caps 4 Remove the spark plugs with a spark plug wrench Spark Plug Inspection 0 8 0 9 mm 0 031 0 035 in To maintain a hot strong spark keep the plugs free from carbon Adjust the gap to 0 8 0 9 mm 0 031...

Page 123: ...lly turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about...

Page 124: ...e two of the most important maintenance items to be performed ENGINE OIL LEVEL CHECK Check the engine oil level with the engine oil dipstick The dipstick comes out together with the oil filler cap as...

Page 125: ...ld the motorcycle vertically Insert the oil dipstick through the oil filler hole The oil filler cap threads should not be run in but should be touching the filler hole upper edge 6 Pull out the oil di...

Page 126: ...always be warm when the engine oil is changed so the engine oil will drain eas ily The procedure is as follows 1 Place the motorcycle on level ground on the side stand 2 Remove the oil filler cap 1 3...

Page 127: ...contact with used engine oil may cause skin can cer Brief contact with oil may irritate skin Keep new and used oil and used oil filters away from children and pets To minimize your exposure to used oi...

Page 128: ...mud or foreign object inside the oil jug or on the oil filter mounting surface Oil filter wrench Part No 09915 40620 NOTICE Turning the engine while draining the engine oil will cause oil film shortag...

Page 129: ...ter 4 with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size and remove the oil filter 5 Wipe off the mounting surface 5 on the engine where the new filter will be s...

Page 130: ...will be felt NOTE To tighten the oil filter properly it is important to accurately identify the position at which the filter gasket first contacts the mounting surface NOTICE Failure to use an oil fi...

Page 131: ...ew one Reinstall the drain plug 2 and gasket 3 Tighten the plug securely with a torque wrench Pour about 3200 ml 3 4 US qt of the specified oil in the filler hole Tighten the oil filler cap Start the...

Page 132: ...l level according to Oil Level Check procedure NOTE Check to see that no oil is leak ing from the oil filter cover NOTICE Engine damage may occur if you use oil that does not meet Suzuki s spec ificat...

Page 133: ...t the throt tle grip has 2 0 4 0 mm 0 08 0 16 in play 3 Tighten the lock nut 1 WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars This can lead...

Page 134: ...Wipe off dirt from the boots with a wet cloth when the boots are dirty ENGINE IDLE SPEED INSPECTION Inspect the engine idle speed The engine idle speed should be 900 1100 r min when the engine is warm...

Page 135: ...UEL HOSE Fuel Tank Lift 1 Place the motorcycle on the side stand Remove the seat by referring to the BATTERY section 2 Remove the bolts 3 Disconnect the coupler 1 and remove the instrument panel assem...

Page 136: ...fuel leakage If any defects are found the fuel hose must be replaced NOTE Lifting up the fuel tank too much can result in the fuel hose becoming bent or twisted Lift the fuel tank as little as possibl...

Page 137: ...easured at the clutch lever end Adjust clutch cable play according to the following procedure Minor Adjustment 10 15 mm 0 4 0 6 in Loosen the lock nut 2 Turn the clutch cable adjuster 1 to provide the...

Page 138: ...th the clutch lever side adjuster 1 4 Tighten the lock nuts 2 and 3 NOTE Check that the clearance between the clutch cable and gearshift rod is more than 6 mm 0 2 in before tightening the lock nuts 3...

Page 139: ...e level is lower than L low level line bring it up to F full level by adding specified engine coolant NOTE Check the coolant level when the engine is cold If the engine coolant reservoir is empty chec...

Page 140: ...ful or fatal if swallowed or inhaled Solution can be poisonous to animals Do not drink antifreeze or coolant solu tion If swallowed do not induce vomit ing Immediately contact a poison control center...

Page 141: ...fects are found ask your Suzuki dealer to replace the radiator hose with a new one FINAL GEAR OIL Change the gear oil as follows 1 Place the motorcycle on the side stand 2 Remove the oil filler cap 1...

Page 142: ...or leaks and the correct level of final gear oil before each use Add oil if necessary Tighten the drain plug securely after changing the gear oil WARNING Children and pets may be harmed by swallowing...

Page 143: ...LE Brake Hose Inspection Inspect the brake hoses and hose joints for cracks damage or brake fluid leak age If any defects are found ask your Suzuki dealer to replace the brake hose with a new one WARN...

Page 144: ...7 49 Brake Fluid FRONT REAR Check the brake fluid level in both the front and rear brake fluid reservoirs If the level in either reservoir is below the lower mark inspect for brake pad wear and leaks...

Page 145: ...Boiling brake fluid or brake system malfunction could result in an acci dent Replace the brake fluid every two years to maintain braking perfor mance WARNING The use of any fluid except DOT4 brake fl...

Page 146: ...t with skin or eyes Solution can be poisonous to animals If brake fluid is swallowed do not induce vomiting Immediately con tact a poison control center or a phy sician If brake fluid gets in eyes flu...

Page 147: ...grooved wear limit lines 1 If a front or rear pad is worn to the grooved wear limit line both front or both rear pads must be replaced with new ones After replacing the front or rear brake pads the b...

Page 148: ...place brake pads have your Suzuki dealer do this work Inspect and maintain the brake pads as recommended WARNING If you ride this motorcycle after brake system repair or brake pad replace ment without...

Page 149: ...urface Adjust the brake pedal position in the following manner WARNING Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an accident A...

Page 150: ...above the top face of the footrest 2 Retighten the lock nut 1 to secure the push rod 2 in the proper posi tion NOTICE An incorrectly adjusted brake pedal may force brake pads to rub against the disk...

Page 151: ...ur motor cycle and the road Failure to take the precautions below may result in an accident due to tire failure Check tire condition and pressure before each ride and adjust pres sure if necessary Avo...

Page 152: ...inflation pressure readings WARNING Failure to perform break in of the tires could cause tire slip and loss of control which could result in an accident Use extra care when riding on new tires Perfor...

Page 153: ...heck the tire for nails or other punctures or a damaged wheel rim Tubeless tires sometimes lose pressure gradually when punctured Tire Condition and Type Tire condition and tire type affect motor cycl...

Page 154: ...t indicates that the tire wear limit has been reached Whenever you replace a tire use a tire of the size and type listed below If you use a different size or type of tire motorcycle handling may be ad...

Page 155: ...wall of each tire WARNING Failure to follow the instructions below for tubeless tires may result in an accident due to tire failure Tube less tires require different service pro cedures than tube tire...

Page 156: ...o not use an external repair plug to repair a puncture since the plug may work loose as a result of the corner ing forces experienced by a motor cycle tire After repairing a tire do not exceed 80 km h...

Page 157: ...ave your motorcycle inspected by an authorized Suzuki dealer or some other qualified service mechanic WARNING If the side stand ignition interlock system is not working properly it is possible to ride...

Page 158: ...2 The special tool is available from a Suzuki dealer 3 Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end Carefully position a jack under the engine or c...

Page 159: ...n the axle counterclockwise and draw it out 5 Slide the front wheel forward NOTE Never squeeze the front brake lever with the wheel removed It is very difficult to force the pads back into the caliper...

Page 160: ...the wheel can cause poor braking performance and may result in an accident Before riding pump the brake lever repeatedly until the brake pads are pressed against the brake disks and proper lever stro...

Page 161: ...CAUTION A hot muffler can burn you Wait until the muffler cools before removing the axle nut NOTICE Removing the rear wheel without use of an accessory stand can result in your motorcycle falling over...

Page 162: ...7 67 3 VL1500T Remove the bolts and sidecase brace 1 and 2 4 Remove the cap...

Page 163: ...3 6 Place an accessory service stand or equivalent under the swingarm or chassis tubes to stabilize the rear end 7 Draw out the axle CAUTION A hot muffler can burn you Wait until the muffler cools be...

Page 164: ...nting bolt 4 Remove the brake caliper assembly 5 9 Remove the wheel from the splined drive gear and set the wheel assem bly on the ground 10 Pull the wheel assembly rearward 11 To replace the wheel re...

Page 165: ...p of SUZUKI THREAD LOCK 1322D to the rear brake caliper bracket mounting bolt 4 WARNING If the bolts and nuts are not properly tightened the wheel can come off causing an accident Be sure to tighten t...

Page 166: ...same wattage rating NOTICE Failure to use a light bulb with the correct wattage rating can overload the electrical system of your motor cycle or cause the bulb to burn out sooner Use only the light bu...

Page 167: ...ight To replace the headlight bulb perform the following steps 1 Remove the right and left bolts Unhook the hooks Remove the headlight cover 1 2 Remove the bolts Unhook the hooks Remove the headlight...

Page 168: ...7 73 3 Disconnect the socket 3 from the headlight and remove the rubber cap 4 4 Unhook the bulb holder spring 5 and pull out the bulb 6...

Page 169: ...oth up and down or right and left if necessary To adjust the beam up and down Turn the adjuster 1 clockwise or coun terclockwise NOTICE The headlight bulb s life may be shortened by oil from your fing...

Page 170: ...eam right and left Turn the adjuster 2 clockwise or coun terclockwise Turn Signal Lights To replace the turn signal light bulbs follow these directions 1 Remove the screw 1 2 Turn the lens countercloc...

Page 171: ...o the left and pull it out 4 To fit the replacement bulb push it in and turn it to the right while pushing NOTICE Overtightening the screws when reinstalling the lens may cause the lens to crack Tight...

Page 172: ...7 77 License Plate Light To replace the license plate light bulb follow the procedure steps 1 Turn the license plate lens counter clockwise and remove it 2 Pull off the bulb from the socket...

Page 173: ...red before replacing the blown fuse with a new fuse Consult your Suzuki dealer for the electrical system check and repair WARNING Replacing a fuse with incorrect amperage rating or substitute e g alum...

Page 174: ...N FUSE The main fuse is located under the front seat One 30A spare fuse is located in the fuse box FUSES The fuses are located under the front seat Two spare fuses 10A and one 15A are provided in the...

Page 175: ...lay fan motor relay side stand relay canister purge sole noid solenoid ECM oxygen sensor fuel pump relay starter relay and ignition coils 10A SIGNAL fuse protects the pilot lamp running light horn spe...

Page 176: ...cial maintenance is required on the converter However it is very important to keep the engine properly tuned Engine misfiring which can result from an improperly tuned engine may cause overheating of...

Page 177: ...stop riding the motorcycle and turn off the engine and have the motorcycle serviced promptly Do not shut off the engine or interrupt the ignition when the transmission is in gear and the motorcycle i...

Page 178: ...8 1 8 TROUBLESHOOTING FUEL SUPPLY CHECK 8 2 IGNITION SYSTEM CHECK 8 3...

Page 179: ...ays FI showing signs of trouble in the fuel injection system take your machine to an authorized Suzuki dealer Refer to the INSTRUMENT PANEL section for an explanation of the fuel injection sys tem ind...

Page 180: ...and the ignition switch in the ON position While holding the spark plug with its base firmly against the engine push the electric starter switch If the ignition system is operating properly a blue sp...

Page 181: ...ion system indicator 3 Check the ignition system for inter mittent spark 4 Check the idle speed The correct idle speed is 900 1100 r min WARNING Performing the spark test improperly can be hazardous Y...

Page 182: ...9 1 9 STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE 9 2 PROCEDURE FOR RETURNING TO SERVICE 9 4 CORROSION PREVENTION 9 4 MOTORCYCLE CLEANING 9 6 INSPECTION AFTER CLEANING 9 10...

Page 183: ...o your authorized Suzuki dealer If you wish to service the machine for storage your self follow the general guidelines below MOTORCYCLE Clean the entire motorcycle Place the motorcycle on the side sta...

Page 184: ...1 Remove the battery from the motor cycle by referring to the BATTERY section 2 Clean the outside of the battery with a mild soap and remove corrosion from the terminals and wiring har ness 3 Store t...

Page 185: ...bricated 7 Perform the INSPECTION BEFORE RIDING as listed in this manual 8 Start the motorcycle as outlined in this manual CORROSION PREVENTION It is important to take good care of your motorcycle to...

Page 186: ...er s directions when using these special cleaners Repair finish damage as soon as possible Carefully examine your motorcycle for damage to the painted surfaces Should you find any chips or scratches i...

Page 187: ...torcycle MOTORCYCLE CLEANING WASHING THE MOTORCYCLE When washing the motorcycle follow the instructions below 1 Remove dirt and mud from the motorcycle with cool running water You may use a soft spong...

Page 188: ...r inlet Throttle cable boots NOTICE High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your motorcy cle It may cause rust corrosion and i...

Page 189: ...m to dry b Stir the paint and touch up the damaged spots lightly with a small brush c Allow the paint to dry completely NOTE The headlight lens can be fogged after washing the motorcycle or riding in...

Page 190: ...es observe the precautions specified by the manufacturers WINDSHIELD CLEANING VL1500T Clean the windshield with soft cloth and warm water with mild detergent If scratched polish with a commercially av...

Page 191: ...ange its appearance INSPECTION AFTER CLEANING For extended life of your motorcycle lubricate it according to the GENERAL LUBRICATION section Follow the procedures in the INSPEC TION BEFORE RIDING sect...

Page 192: ...ARRANTIES 10 2 EMISSION CONTROL SYSTEMS 10 3 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 10 4 ON BOARD MOTORCYCLE COMPUTER DATA INFORMATION 10 5 SERIAL NUMBER LOCATION 10 6 REPORTING SAFETY DEFECTS...

Page 193: ...Control System Limited Warranty Applies ONLY to Suzuki street legal emission con trolled motorcycles certified for sale and registered in California Suzuki limited warranties and the Fed eral and Cal...

Page 194: ...s and electronic control units Evaporative Emission Control System if equipped The evaporative emission control system of your vehicle consists of the carbon can ister fuel tank fuel hoses and fuel va...

Page 195: ...any person Among those acts presumed to consti tute tampering are the acts listed below removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other comp...

Page 196: ...may be stored by the on board computer when malfunctions occur This stored information can assist technicians in repairing the motorcycle To read the stored informa tion special equipment is needed an...

Page 197: ...cycle You also need these numbers to help your authorized Suzuki dealer when you order parts The frame number 1 is stamped on the steering head as shown in the illustra tion The engine serial number 2...

Page 198: ...etween you your dealer or Suzuki Motor of America Inc To contact NHTSA you may either call the Vehicle Safety Hot Line toll free 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write...

Page 199: ...any reason 1 2 WARNING To reduce the risk of injury Wear a helmet eye protection and protective clothing Read owner s manual carefully Theowner smanual containsimportantsafety informationandinstructi...

Page 200: ...taire pour plus d informations This unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat Read owner s manual for more information BRIDGESTONE kgf cm2...

Page 201: ...RMS TO U S EPA REGULATIONS APPLICABLE TO MODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO HC NOx ENGINE FAMILY EXHAUST EMISSION STANDARD VALVE LASH FUEL ENGINE TUNE UP SPECIFICATIONS ALL ADJUSTMENTS ARE...

Page 202: ...ALIFORNIA REGULATIONS APPLICABLE TO MODEL YEAR NEW MOTORCYCLES VALVE LASH FUEL ENGINE TUNE UP SPECIFICATIONS ALL ADJUSTMENTS ARE TO BE PERFORMED WITH TRANSMISSION IN NEUTRAL ENGINE FAMILY EVAP FAMILY...

Page 203: ...maximum loading capacity for each sidecase Balance the load between the right and left sides of the motorcycle Make sure the lid of the sidecase is locked with a key before riding Read the owner s ma...

Page 204: ......

Page 205: ...clearance 140 mm 5 5 in Seat height 720 mm 28 3 in Curb mass 344 kg 758 lbs 363 kg 800 lbs VL1500T ENGINE Type Four stroke liquid cooled SOHC 54 degree V twin Number of cylinders 2 Bore 96 0 mm 3 780...

Page 206: ...tion ratio 3 137 20 17 32 12 Drive system Shaft drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front fork stroke 130 mm 5 1 in Rear w...

Page 207: ...10 15 10 10 15 10A Headlight 12V 60 55W H4 Brake light Taillight LED Front turn signal light 12V 21W Rear turn signal light 12V 21W License plate light 12V 5W Speedometer light LED High beam indicato...

Page 208: ...CAPACITIES Fuel tank 18 0 L 4 8 US gal Engine oil without filter change 3000 ml 3 2 US qt With filter change 3200 ml 3 4 US qt Final gear oil 200 220 ml 6 8 7 4 US oz Engine coolant 2650 ml 2 8 US qt...

Page 209: ...TY CONSCIOUS ON BAD WEATHER DAYS 1 6 BE STREET SMART 1 9 BRAKES 7 48 BREAK IN 4 2 C CARRYING A PASSENGER 1 8 5 12 CATALYTIC CONVERTER 7 81 CLUTCH ADJUSTMENT 7 42 CONCLUSION 1 10 CORROSION PREVENTION 9...

Page 210: ...LEVER 3 28 GENERAL LUBRICATION 7 8 H HELMET HOLDER 3 30 I IF A COLLISION IS IMMINENT DO SOMETHING 1 4 IF YOU DON T HAVE A HELMET BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE 1 3 IGNITION SWITCH 3 5 IG...

Page 211: ...OST ACCIDENTS CAN BE AVOIDED 1 3 MOTORCYCLE CLEANING 9 6 MOTORCYCLE SAFETY FOUNDATION S RIDING TIPS AND PRACTICE GUIDE HANDBOOK FOR OWNERS IN USA 1 9 O ON BOARD MOTORCYCLE COMPUTER DATA INFORMATION 10...

Page 212: ...CIAL SITUATIONS REQUIRE SPECIAL CARE 1 5 STARTING OFF AND SHIFTING 5 5 STARTING THE ENGINE 5 2 STEERING LOCK 3 7 STOPPING AND PARKING 5 10 STORAGE PROCEDURE 9 2 T TAMPERING WITH NOISE CONTROL SYSTEM P...

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