Suzuki 2004 VL800 User manual

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VL800 ii
OWNER'S MANUAL
This owner's manual contains
important safety information.
Plef3se read it carefully.
* SUZUKI
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California Proposition 65 Warning
A WARNING
Engine exhaust, some of its constituents, and certain product com-
ponents contain or emit chemicals known to the State of Caliornia
to cause cancer and birth defects or other reproductive harm.
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This manual should be considered a permanent part of the
motorcycle and should remain with the motorcycle when resold
or otherwise transferred to a new owner or operator. The
manual contains important safety information and instructions
which should be read carefully before operating the motorcycle.
,
.,

IMPORTANT
W ARNING/CAUTION/NOTE ,
Please read this manual and fol-
low its instructions carefully. To
emphasize special information,
the symbol A. and the words
WARNING, CAUTION and NOTE
have special meanings. Pay spe-
cial attention to the messages
highlighted by these signal words:
AWARNING
Indicates a potential hazard
that could result in death or
injury.
CAUTION
Indicates a potential hazard
that could result in motorcycle
damage.
NOTE: Indicates special informa-
tion to make maintenance easier
or instructions clearer.
WARNINGs and CAUTIONs are
arranged like this:
A W ARNING-or-CAUTION
The first part wil describe a
POTENTIAL HAZARD and
WHAT CAN HAPPEN if you
ignore the WARNING or CAU-
TION.
The second part will describe
HOW TO AVOID THE HAZARD.
:1
FOREWORD
Motorcycling is one of the most
exhilarating sports and to ensure
your riding enjoyment, you should
become thoroughly familiar with
the information presented in this
Owner's Manual before riding the
motorcycle.
The proper care and maintenance
that your motorcycle requires is
outlined in this manuaL. By follow-
ing these instructions explicitly
you will ensure a long trouble-free
operating life for your motorcyCle.
This motorcycle also conforms to
the U.S Environmental Protection
Agency emission regulations
which apply to new motorcycles.
The proper adjustment of engine
components is necessary for this
motorcycle to comply with the
EPA regulations. Therefore,
please follow the maintenance
instructions closely to ensure
emission compliance. Your autho-
rized Suzuki dealer has experi-
enced technicians that are trained
to provide your machine with the
best possible service with the
right tools and equipment.
SUZUKI MOTOR CORPORATION
1

All information, illustrations, and
specifications contained in this
manual are based on the latest
product information available at
the time of publication. Due to
improvements or other changes,
there may be some discrepancies
in this manuaL. Suzuki reserves
the right to make production
changes at any time, without
notice and without incurring any
obligation to make the same or
similar changes to vehicles previ-
ously built or sold.
Suzuki Motor Corporation
believes in conservation and pro-
tection of Earth's Natural
resources. To that end, we
encourage every vehicle owner to
recycle, trade in, or properly dis-
pose of, as appropriate, used
motor oil, engine coolant, and
other fluids, batteries, and tires.
(Ç COPYRIGHT SUZUKI MOTOR
CORPORATION 2003
TABLE OF CONTENTS
THE SPORT OF
MOTORCYCLING ........................4
FUEL, OIL AND COOLANT
RECOMMENDATION ..................9
FUEL ................................................9
ENGINE OIL ...............................10
GEAR OIL ..................................10
ENGINE COOLANT SOLUTION ......11
LOCATION OF LABELS ............12
LOCATION OF PARTS ...............13
CONTROLS, EQUIPMENT.
AN ADmSTMENTS .................16
KEY' .........................................16
IGNITION SWITCH ......................16
INSTRUMENT PANEL ..................18
LEFT HANDLEBAR .....................22
RIGHT HANDLEBAR ....................23
FUEL TANK CAP .........'...............25
CHOKE KNOB ..............................26
GEARSHIFT LEVER ........................26
REAR BRAKE PEDAL .................27
HELMET HOLDER .....................27
SIDE STAND ..............................28
SUSPENSION ADJUSTMENT ........29
BREAK-IN ....................................30
INSPECTION BEFORE RIDING 32
RIDING TIPS ...............................33
STARTING THE ENGINE ..............33
STARTING OFF AND SHIFTING ....35
USING THE TRANSMISSION .........36
RIDING ON HILLS .........................37
STOPPING AND PARKING ...........37
CARRYING A PASSENGER ..........38
ACCESSORY USE AN
MOTORCYCLE LOADING ........39
MODIFICATION ..........................40
INSPECTION AND
MAINTENANCE .........................41
NOTICE .........................................41
MAINTENANCE SCHEDULE .........41
2

TOOLS ...........................................44
GENERAL LUBRICATION .............44
BATTERY .....................................45
AIR CLEANER ..........................46
SPARK PLUG ................................49
ENGINE OIL ...............................52
CARBURETOR ..............................56
FUEL HOSE .................................57
CLUTCH ADJUSTMENT ..............58
ENGINE COOLANT ......................58
FINAL GEAR OIL ........................59
BRAKES .......................................60
TIRES ..........................................65
SIDE STAND/IGNITION
INTERLOCK SYSTEM ..................68
FRONT WHEEL REMOVAL ............69
REAR WHEEL REMOVAL .............70
LIGHT BULB REPLACEMENT ......72
FUSES ......................................... 75
TROUBLESHOOTING ............... 77
STORAGE PROCEDURE ...........80
APPEARANCE CARE ................ 82
CORROSION PREVENTION .........82
MOTORCYCLE CLEANING .............83
INSPECTION AFTER CLEANING ..84
CONSUMER INORMATION ...85
EMISSION CONTROL
WARRANTY ..................................85
TAMPERING WITH NOISE
CONTROL SYSTEM
PROHIBITED ................................85
SERIAL NUMBER LOCATION ......86
REPORTING SAFETY DEFECTS ....87
SPECIFCATIONS .......................88
..
3

THE SPORT OF
MOTORCYCLING
Your motorcycle and this owner's
manual have been designed by
people like you who enjoy motor-
cycling. People become motorcy-
clists for many reasons. For
starters, street riding is fun and
invigorating. But no matter why
you became a motorcyclist, ~r
how experienced you are, you will
eventually face some challenging
situations.
In preparing for these challenges,
you will be fine-tuning your coo~-
dination, concentration, and atti-
tude. Learning the skills and
strategies associated with motor-
cycling is the basis for safely par-
ticipating in this sport. Many
motorcyclists find that as they
become better riders, they also
get more enjoyment fro~ the free-
dom unique to motorcycling.
Please remember:
Most accidents can be avoided.
The most common type of motor-
cycle accident in the U.S. occurs
when a car traveling toward a
motorcycle turns left in front of the
motorcycle. Is that because other
drivers are out to get motorcy-
clists? No. Other drivers simply
don't always notice motorcyclists.
Ride defensively. Wise motorcy-
clists use a strategy of assuming
they are invisible to other drivers,
even in broad daylight. Pay care-
ful attention to other motorists,
especially at intersectio~s,
because they may not be paying
attention to you. Select a lane
position that gives you the best
view of others, and other motor-
ists the best view of you. Wear
bright, reflective clothing. Put
reflective strips on your helmet.
4

If you don't have a helmet: buy
a helmet, and wear it EVERY
TIME YOU RIDE.
Most accidents occur within a few
miles of home, and almost half
occur at speeds of less than 30
mph. So even if you're just going
on a quick errand, be prepared-
strap on your helmet before you
take off.
Helmets do not reduce essential
vision or hearing. Generally, hel-
mets do not cause or intensify
injury if you crash. Helmets simply
help your skull protect your intell-
gence, your memory, your per-
sonality, and your life.
Your eyesight is equally valuable.
Wearing suitable eye protection
can help keep your vision
unblurred by the wind and save
your eyes from airborne hazards
like bugs, dirt, or pebbles kicked
up by tires.
If a collsion is imminent, DO
SOMETHING!
Many riders fear locking up their
brakes or haven't learned to
. swerve to avoid an accident.
Many inexperienced riders (and
too many seasoned riders) use
only their rear brake in an emer-
gency, resulting in unnecessary
impacts in some cases and
unnecessarily high impact speeds
in other cases. Your rear brake
can only provide about 30% of
your motorcycle's potential stop-
ping power. The front and rear
brakes can and should be used
together to maximize braking
effectiveness.
Experienced motorcyclists learn
to "covet' the front brake lever by
lightly resting a couple of fingers
over the lever when riding in traf-
fic and near intersections to give
their reaction time a head start.
5

Emergency stopping and swerv-
ing are techniques that you
should practice and master before
you find yourself in an emergency
situation. The best place to prac-
tice such techniques is in a con-
trolled environment such as the
Motorcycle Safety Foundation's
(MSF) rider training courses. The
MSF's Motorcycle RiderCourses
(fundamental techniques) and
Experienced RiderCourses
(advanced strategies) present
hands-on instruction of the basic
principles of motorcycling and a
variety of accident avoidance
maneuvers. Even a seasoned
motorcyclist can improve his or
her riding skills, and pick up a few
new skills, through these courses.
Some insuranCe companies even
offer discounts to course gradu-
ates.
Special situations require
special care.
Of course, there are some times
when full-force braking is not the
correct technique. When the road
surface is wet, loose, or rough,
you should brake with care. When
you're leaned over in a corner,
avoid braking. Straighten up
before braking. Better yet, slow
down before entering the corner.
In these situations, the traction
available between your tires and
the road surface is limited. Over-
braking when traction is limited
will cause your tires to skid, possi-
bly resulting in loss of directional
control or causing you and your
motorcycle to fall over.
Know your limits.
Always ride within the boundaries
of your own skills. Knowing these
limits and staying within them will
help you avoid accidents.
A major cause of accidents
involving only a motorcycle (and
no cars) is going too fast through
a turn. Before entering a turn,
select an appropriately low cor-
nering speed.
Even on straight roads, ride at a
speed that is appropriate for the
traffic, visibility and road condi-
tions, your motorcycle, and your
experience.
6

Riding a motorcycle safely
requires that your mental and
physical skills are fully part of the
experience. You should not
attempt to operate a motor vehi-
cle, especially one with two
wheels, if you are tired or under
the influence of alcohol or other
drugs. Alcohol, illegal drugs, and
even some prescription and over-
the-counter drugs can cause
drowsiness, loss of coordination,
loss of balance, and especially
the loss of good judgment. If you
are tired or under the influence of
alcohol or other drugs, PLEASE
DO NOT RIDE your motorcycle.
Be extra safety-conscious on
bad weather days.
Riding on bad weather days,
especially wet ones, requires
extra caution. Braking distances
increase on a rainy day. Stay off
the painted surface marks, man-
hole covers, and greasyappearing
areas, as they can be especially
slippery. Use extra caution at rail-
way crossings and on metal grat-
ings and bridges. When it starts to
rain, any oil or grease on the road
rises to the surface of the water.
Pull over and wait a few minutes
until this oil film is washed away
before riding. Whenever in doubt
about road conditions, slow down!
Practice away from traffic.
Your riding skill and your mechan-
ical knowledge form the founda-
tion for safe riding practices. We
suggest that you practice riding
your motorcycle in a nontraffc sit-
uation until you are thoroughly
familiar with your machine and its
controls. Again, consider taking
one of the MSF's HiderCourses.
Even experts will be pleased with
the caliber of the information pre-
sented in these courses. As the
MSF says: "The more you know,
the better it gets!"
Inspection before riding.
Review the instructions in the
INSPECTION BEFORE RIDING
section of this manuaL. Perform
an entire pre-ride inspection
before you head out on the road.
Spending a few minutes prepar-
ing your machine for a ride can
help prevent accidents due to
mechanical failure or costly,
inconvenient breakdowns far from
home.
Accessories and Loading.
The accessories you use with
your motorcycle and the manner
in which you load your gear onto
the bike might create hazards.
Aerodynamics, handling, balance,
and cornering clearance can suf-
fer, and the suspension and tires
can be overloaded. Read the
ACCESSORY USE AND
MOTORCYCLE LOADING sec-
tion.
7

Carrying a Passenger.
Carrying a passenger, when done
correctly, is a 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 handling
and braking. You may also need
to adjust tire pressures and sus-
pension; please refer to the Tire
Pressure and Loading section
and the Suspension section for
more details.
A passenger needs the same pro-
tectionthat you do, including a
helmet and proper clothing. The
passenger should not wear long
shoe laces or loose pants that
could get caught in the wheel or
the chain. Passengers must be
tall enough that their feet reach
the footrests.
Motorcycle Safety
Foundation's "Riding Tips and
Practice Guide" Handbook
(for owners in USA).
This special handbook, supplied
with your owner's manual, con-
tains a variety of safety tips, help-
ful hints, and practice exercises.
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-
ers by demonstrating a courteous
atttude and a responsible riding
style.
Conclusion.
Traffic, road and weather condi-
tions vary. Other motorist's
actions are unpredictable. Your
motorcycle's condition can
change. These factors can best
be dealt with by giving every ride
your full attention.
Circumstances beyond your con-
trol could lead to an accident. You
need to prepare for the unex-
pected by wearing a helmet and
other protective gear, and learn-
ing emergency braking and
swerving techniques to minimize
the damage to you and your
machine.
The best way to learn basic riding
skils and evasive maneuvers or
refresh your own riding skils is to
take one of the courses offered by
the Motorcycle Safety Founda-
tion. Your authorized Suzuki
dealer can help you locate the
fundamental or advanced riding
skills course nearest you, or own-
ers in the USA can call toll-free 1-
800-446-9227.
Good riding on your new Suzuki!
8

FUEL, OIL AND
COOLANT
RECOMMENDATION
FUEL
Your motorcycle requires regular
unleaded gasoline with a mini-
mum pump octane rating of 87
((R+M)/2 method). In some areas,
the only fuels that are available
are oxygenated fuels.
Oxygenated fuels which meet the
minimum octane requirement and
the requirements described below
may be used in your motorcycle
without jeopardizing the. New
Vehicle Limited Warranty or the
Emission Control System War-
ranty.
NOTE: Oxygenated fuels are
fuels which contain oxygen-carry-
ing additives such as MTBE or
alcohol.
Gasoline containing MTBE
Unleaded gasoline containing
MTBE (Methyl Tertiary Butyl
Ether) may be used in your motor-
cycle if the MTBE content is not
greater than 15%. This oxygen-
ated fuel does not contain alco-
hoL.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and
ethanol (grain alcohol), also
known as "GASOHOL", may be
used in your vehicle if the ethanol
content is not greater than 10%.
Gasoline/Methanol Blends
Fuel containing 5% or less metha-
nol (wood alcohol) may be suit-
able for use in your motorcycle if
they contain co-solvents and cor-
rosion inhibitors. DO NOT USE
fuels containing more than 5%
. methanol under any circum-
stances. Fuel system damage or
motorcycle performance prob-
lems resulting from the use of
such fuels are not the responsibil-
ity of Suzuki and may not be cov-
ered under the New Vehicle
Limited Warranty or the Emission
Control System Warranty.
Fuel Pump Labeling
In some states, pumps that dis-
pense oxygenated fuels are
required to be labeled for the type
and percentage of oxygenate,
and whether important additives
are present. Such labels may pro-
vide enough information for you to
determine if a particular blend of
fuel meets the requirements listed
above. In other states, pumps
may not be clearly labeled as to
the content or type of oxygenate
and additives. If you are not sure
that the fuel you intend to use
meets these requirements, check
with the service station operator
or the fuel suppliers.
9

NOTE:
. To help clean the air, Suzuki
recommends that you use the
oxygenated fuels.
. Be sure that any oxygenated
fuel you use has octane rat-
ings of at least 87 pump
octane ((R+M)/2 method).
. If you are not satisfied with the
driveability of your motorcycle
when you are using an oxy-
genated fuel, or if engine ping-
ing is experienced, substitute
another brand as there are dif~
ferences between brands.
CAUTION
Spiled gasoline containing
alcohol can harm your motor-
cycle. Alcohol can damage
painted surfaces.
Be careful not to spil any fuel
when filing the fuel tank. Wipe
spiled gasoline up immedi-
ately.
ENGINE OIL
Suzuki recommends the use of
SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is
rated SF or SG under the API ser-
vice classification. The recom-
mended viscosity is SAE 10W-40.
If an SAE 10W-40 oil is not avail-
able, select an alternative accord-
ing to the following chart.
GEAR OIL
Use an SAE90 hyopid gear oil
which is rated GL-5 under the API
classification system. If you oper-
ate the motorcycle where ambient
temperature is below O°C (23°F),
use SAE80 hypoid gear oiL.
I I
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ENGINE OIL i"II
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'C -30 -20 -10 0 10 20 30 40
TEMP. 'F -22 -4 14 32 50 68 86 104
10

ENGINE COOLANT SOLUTION
Use engine coolant that is com-
patible with an aluminum radiator,
mixed with distilled water at a
50:50 mixture ratio for engine
coolant solution. An engine cool-
ant mixture other than 50:50 can
affect cooling efficiency or rust
inhibiting performance.
Engine Coolant
Engine coolant should be used at
all times in your motorcycle's radi-
ator, even if the temperature in
your area does not go down to the
freezing point. Engine coolant
acts as a rust inhibitor and water
pump lubricant as well as an anti-
freeze solution.
Engine coolant is harmful or
fatal if swallowed or inhaled.
Do not drink antifreeze or cool-
ant solution. If swallowed, do
not induce vomiting. Immedi-
ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Solution can be
poisonous to animals. Keep
out of the reach of children and
animals.
CAUTION
Spiled engine coolant can
damage painted surfaces.
Do not spil any fluid when fil-
ing the radiator. Wipe spiled
engine coolant up immediately.
Water for Mixing
Use distilled water only. Water
other than distilled water can cor-
rode and clog the aluminum radi-
ator.
Required amount of engine cool-
anVwater solution capacity (total):
1500 ml (3.2 US pt)
Engine coolant 750 ml
(1.6 USpt)
Water 750ml
(1.6 US pt)
11

LOCATION OF LABELS
Read and follow all of the warn-
ings labeled on your motorcycle.
Make sure you understand all of
the labels. Keep the labels on
your motorcycle. Do not remove
them for any reason.
(î
The owner's manual contains
important safety information
and instructions which should
be read carefully before operat-
ing the vehicle.
If the vehicle has been resold,
obtain the owner's manual from
the previous owner or contact
your local SUZUKI dealer for
assistance.
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AWARNING
Failure to follow these safety
precautions may increase your
risk of injury:
. Wear a helmet, eye protec-
tion, and bright protective
clothing.
. Don't ride after consuming
alcohol or other drugs.
. Slow down on slippery sur-
faces, unfamilar. terrain, or
when visibilty is reduced.
. Read owner's manual care-
fully.
.A WARNING COLD TIRE
PRESSURE
FRONT
REAR
. Check tire condition,
wear, and cold tire
pressure before each ride.
. Replace only with tires
of listèd size and type.
. Read Owner's manual for
more information.
TIRE SIZE
TYPE IRC
I
12
SOLO RIDING
kPa kgf/cm' psi
200 2.00 29
250 2.50 36
FRONT
DUAL RIDING
kPa kgf/cm' psi
200 2.00 29
250 2.50 36
REAR
170/80-15M/C 77H
GS-23R
130/90-1667H
GS-23F

LOCATION OF PARTS
CD ~ Q) ~ (( (§ CD
CI
CD Clutch lever
(2 Left handlebar switches
Q) Speedometer
~ Front brake fluid reservoir
(( Right handlebar switches
(§ Throttle grip
ø Front brake lever
CI Fuel tank cap
13

CI (i
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G§ (j ~ ~ (í
CI Throttle stop screw
G: Spark plug
(j Battery and main fuse
(j Tools
~ Helmet holder
(ß Gearshift lever
(j Footrests
(f Choke knob
CD Side stand
Q§ Engine coolant reservoir
(i Fuses
(í Passenger footrests
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~ ~ ~ 0I (2 'Í ~
Cí
(Í Air cleaner
~ Ignition switch
~ Engine oil filler cap
~ Engine oil inspection window
~ Engine oil drain plug
(Í Engine oil filter
(j Rear brake light switch
(Í Rear brake pedal
15

CONTROLS, EQUIPMENT
AND ADJUSTMENTS
KEY
D
Two keys come with this motorcy-
cle. Keep the spare key in a safe
place. An identifying number is
stamped on the plate. Use this
number when making a replace-
ment key.
Please write down your key num-
ber in the box provided for your
future reference.
I Key number:
IGNITION SWITCH
The ignition switch has 4 posi-
tions.
"OFF" position
All electrical circuits are cut off.
The engine will not start. The key
can be removed.
"ON" position
The ignition circuit is completed
and the engine can be started.
The headlight and taillght will
automatically turn on. The key
cannot be removed in this posi-
tion.
I NOTE: Start the engine promptly
after turning the key to the "ON"
position, or the battery wil lose
power due to consumption by the
headlight and taillght.
"LOCK" position
All electrical circuits are off. The
key can be removed and the
steering will be locked. Turn the
steering all the way to the left and
push down the key and turn it to
the "LOCK" position.
16

"P" (PARKING) position
Tailight will come on to increase
visibility for temporary road side
parking at night. The key can be
removed and the steering will be
locked.
AWARNING
Turning the ignition switch to
the "P" (PARKING) or "LOCK"
position while the motorcycle
is moving can be hazardous.
Moving the motorcycle while
the steering is locked can be
hazardous. You could lose
your balance and fall, or you
could drop the motorcycle.
Stop the motorcycle and place
it on the side stand before lock-
ing the steering. Never attempt
to move the motorcycle when
the steering is locked.
NOTE: The key hole can be cov-
ered by turning the lid for anti-
theft purpose.
Turn the ignition switch to "LOCK"
position and change the lid hole
position when leaving your motor-
cycle.
D
Align the lid hole position with the
key hole position when inserting
the key.
17

INSTRUMENT PANEL
:%)~I-.
Y1~r
~~.
Q) (4 CI CI CV CI (I
SPEEDOMETER CD
The speedometer indicates the
road speed in kilometers per hour
and miles per hour.
ODOMETERIRIPMETERI
CLOCK/FUEL METER ~
The display in the speedometer
has four functions, clock, odome-
ter and two trip meters. When the
ignition switch is turned to the
"ON" position, the display indi-
cates the test pattern shown
below for three seconds. Then the
disply changes to odometer.
00000
aDO TRlpSm
1-' I-' 0 0 l' ''
t, bC':Lib.b
To change the display, push the
button CI. The display changes in
the order below.
00000
ODO
000003
Odometer
.
00000
TRlpm
., n
U.U
Trip meter m
.
00000
TRIP ii
., n
U.U
Trip meter m
.
00000
3:33
Clock
18