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.
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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
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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
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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
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