Suzuki Intruder VL800 User manual

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
SHAFT DRIVE 4
FUEL AND LUBRICATION SYSTEM 5
COOLING SYSTEM 6
CHASSIS 7
ELECTRICAL SYSTEM 8
SERVICING INFORMATION 9
EMISSION CONTROL INFORMATION 10
Revised 09/07

17
16
VL800/TK6 ('06- MODEL)
15
VL800TK5 ('05- MODEL)
14
VL800K5 ('05- MODEL)
13
VL800K4 ('04- MODEL)
12
VL800K3 ('03- MODEL)
11
VL800K2 ('02- MODEL)
SUPPLEMENTS
VL800/C/TK9 (”09 MODEL) 18
VL800/TK7 & TK8 ('07&’08- MODEL)
WIRING DIAGRAM 19

HOWTO USETHIS MANUAL
TO LOCATE WHATYOU ARE
LOOKING FOR:
1.The text of this manual is divided into sections.
2.The section titles are listed in the GROUP INDEX.
3.Holding the manual as shown at the right will allow you
to find the first page of the section easily.
4.The contents are listed on the first page of each section
to help find the item and page you need.
COMPONENT PARTS AND WORKTO BE DONE
Under the name of each system or unit, is its exploded view.Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1Frontaxle
2Bearing(R)
3Frontwheel
4Spacer
5Bearing(L)
6Brakedisc
7Spacer
AFrontaxle
BBrakediscmountingbolt
!
ITEM N.m kgf.m lb-ft
A65 6.5 47.0
B23 2.3 16.5

SYMBOL (For USA)
Listed in the table below are the symbols indicating instructions and other information necessary for
servicing. The meaning of each symbol is also included in the table.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI SUPER GREASE “A”.
99000-25030
Apply THREAD LOCK “1342”.
99000-32050
Apply THREAD LOCK SUPER
“1360”
99000-32130
Apply or use brake fluid.
Apply SUZUKI BOND “1207B”
99104-31140
Apply THREAD LOCK SUPER
“1303”.
99000-32030
Measure in voltage range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use engine coolant.
99000-99032-11X
Use fork oil.
99000-99001 SS8
SYMBOL DEFINITION SYMBOL DEFINITION
Indication of service data.
Apply SUZUKI MOLY PASTE.
99000-25140
"Apply SUZUKI BOND “1216”
99104-31160
#Measure in resistance range.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)

SYMBOL (For the other countries)
Listed in the table below are the symbols indicating instructions and other information necessary for
servicing.The meaning of each symbol is also included in the table.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI SUPER GREASE “A”.
99000-25010
Apply THREAD LOCK “1342”.
99000-32050
Apply THREAD LOCK SUPER
“1360”.
99000-32130
Apply or use brake fluid.
Apply SUZUKI BOND “1207B”.
99000-31140
Apply THREAD LOCK SUPER
“1303”.
99000-32030
Measure in voltage range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use engine coolant.
99000-99032-11X
Use fork oil.
99000-99001-SS8
SYMBOL DEFINITION SYMBOL DEFINITION
Indication of service data.
Apply SUZUKI MOLY PASTE.
99000-25140
"Apply SUZUKI BOND “1216”.
99104-31160
#Measure in resistance range.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)

GENERAL INFORMATION 1-1
CONTENTS
GENERAL INFORMATION
1

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad-
vice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When two or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until
they have cooled.
* After servicing the fuel, oil, engine coolant, exhaust or brake systems,check all of the lines and
fittings related to the system for leaks.

GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricants, bonds, or sealants.
* When removing the battery,disconnect the -battery lead wire first and then the +battery lead
wire.
* When reconnecting the battery, connect the +battery lead wire first, then the -battery lead
wire. Finally, cover the +battery terminal with the terminal cover.
* When performing service to electrical parts, disconnect the -battery lead wire, unless the
service procedure requires the battery power.
* When tightening cylinder head and crankcase nuts and bolts tighten the larger sizes first.
Always tighten the nuts and bolts from the inside working out diagonally and to the specified
torque.
* Whenever you remove oil seals, gaskets, packing, O rings, self-locking nuts, locking washers,
cotter pins, circlips, and other specified parts, be sure to replace them with new ones. Also,
before installing these new parts, be sure to remove any left over material from the mating
surfaces.
* Never reuse a circlip.When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant, all
other fluids, batteries, and ti es.
* To protect the earth’s natural resources, properly dispose of used motorcycles and parts.

1-4 GENERAL INFORMATION
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1is stamped on the right side of the
steering head pipe.The engine serial number 2is located on the right s de of the crankcase.These numbers
are required especially for registering the machine and ordering spare parts.
* Difference between photograph and actual motorcycle depends on the markets.
RIGHT SIDE LEFT SIDE
SUZUKI VL800K1 (2001-MODEL)
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (For USA and CANADA)
1.Use only unleaded gasoline o at least 87 pump octane ( ) method or 91 octane or higher rated by the
Research Method.
2.Suzuki recommends that customers use alcohol-free unleaded gasoline whenever possible.
3.Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
4.Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha-
nol.Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors
are present in it.
5.If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should
switch to alcohol-free unleaded gasoline.
6.Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel
supplier to make sure that the fuel you intend to use meets the requirements listed above.
FUEL (For the other countries)
Use unleaded gasoline that is graded 91 octane or higher by the Research Method.

GENERAL INFORMATION 1-5
ENGINE OIL (For USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SF or SG under the API
(American Petroleum Institute) service classification.The recom-
mended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not
available, select an alternative according to the right chart.
ENGINE OIL (For the other countries)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification. The recommended vis-
cosity is SAE 10W-40. If an SAE 10W-40 motor oil is not avail-
able, select an alternative according to the right chart.
BRAKE FLUID
#Specification and classification: DOT 4
!
* This motorcycle uses a glycol-based brake fluid. Do not use or mix other types of brake fluid
such as silicone-based and petroleum based fluids for refilling the system, otherwise serious
damage will result to the brake system.
* Do not use any brake fluid taken from old used, or unsealed containers.
* Do not re-use brake fluid left over from last servicing or which has been stored for a long period
of time.
MULTIGRADE
TEMP.
GEAR OIL (FINAL DRIVE GEAR OIL)
Use SAE 90 hypoid gear oil which is reted GL-5 under API classification system. If you operate the motor-
cycle where ambient temperature is below 0°C (32°F), use SAE 80 hypoid gear oil.
FRONT FORK OIL
Use SUZUKI FORK OIL SS-08 (#10) or an equivalent fork oil.
ENGINE COOLANT
Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing
antifreeze, even if the atmospheric temperature does not go below the freezing point.
Use an antifreeze designed for aluminum radiators. Suzuki recommends the use of SUZUKI COOLANT
antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators.
Mix only distilled water with the antifreeze.Other types of water can corrode and clog the aluminum radiator.
Mix distilled water and antifreeze at a ratio of 50 : 50 – 40 : 60.
For more information, refer to cooling system section. ($6-2)
"
The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of
antifreeze is above or below this range the coolant’s frost protection and rust-inhabiting capaci-
ties will be reduced. Always keep the antifreeze content above 50% even if the atmospheric tem-
perature does not go below the freezing point.

1-6 GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very
high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to
maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. Refer to the following break-in engine speed recommendations.
• Keep to these break-in throttle positions during the break-in period.
Break-in throttle operation
Initial 800 km ( 500 miles): Less than ½ throttle
Up to 1 600 km (1 000 miles): Less than ¾ throttle
• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the mo orcycle to full throttle
operation.
CYLINDER IDENTIFICATION
The engine cylinders are identified as #1 and #2, as counted
from rear to front (as viewed by the rider on the seat).
#1
#1
#2
#2

GENERAL INFORMATION 1-7
INFORMATION LABELS
NO. LABEL or PLATE NAME APPLIED SPECIFICATION
E-02 E-03 E-19 E-24 E-28 E-33
1Noise label –– –
2Information label –––
3Vacuum hose routing label –––––
4Fuel caution label –– ––
5Manual notice label ––––
6Tire air pressure label
7Warning safety label
8ICES Canada label –––– –
9ID plate –––
0Safety plate –––
Right side Left side
E-03, E-28, E-33
E-03, E-33
E-24
E-02, E-24, E-19

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length................................................................ 2 510 mm (98.818 in)
Overall width ................................................................. 985 mm (38.779 in)
Overall height................................................................ 1 110 mm (43.700 in)
Wheelbase.................................................................... 1 650 mm (64.960 in)
Ground clearnce ........................................................... 140 mm ( 5.511 in)
Seat height.................................................................... 700 mm (27.559 in)
Dry mass....................................................................... 239 kg (53.727 lbs)
ENGINE
Type............................................................................... Four-stroke, Liquid-cooled, OHC
Number of cylinders...................................................... 2
Bore .............................................................................. 83 mm (3.268 in)
Stroke............................................................................ 74.4 mm (2.929 in)
Displacement ................................................................ 805 cm3(49.1 cu in)
Compression ratio......................................................... 9.4 : 1
Carburetor..................................................................... BDSR34
Air cleaner..................................................................... Non-woven fabric element
Starter system............................................................... Electric
Lubrication system........................................................ Wet sump
Idle speed ..................................................................... 1 100 ± 100 r/min
TRANSMISSION
Clutch....................................................................... .. Wet multi-plate type
Transmission ...................................................... .. 5-speed, constant mesh
Gearshift pattern ............................................... .... ... 1-down, 4-up
Primary reduction ratio ............................. ............ ..... 1.690 (71/42)
Secondary reduction ratio ...................... ...... ............ 1.133 (17/15)
Final reduction ratio ........................... .. ............ 3.090 (34/11)
Gear ratios, Low ............................... .... .................. 2.461 (32/13)
2nd......................... ......... ..................... 1.631 (31/19)
3rd .................... . ....... ........................ 1.227 (27/22)
4th.......................... .... ........................... 1.000 (25/25)
Top.................... ... ............................... 0.814 (22/27)
Drive system .................... ...... .................................. Shaft drive

GENERAL INFORMATION 1-9
CHASSIS
Front suspension .......................................................... Telescopic, coil spring, oil damped
Rear suspension........................................................... Link type, coil spring, oil damped, spring pre-load
7-way adjustable
Steering angle .............................................................. 38°(right & left)
Caster ........................................................................... 33°20’
Trail................................................................................ 141 mm (3.55 in)
Turning radius ............................................................... 3.0 m (9.8 ft)
Front brake.................................................................... Disc brake
Rear brake .................................................................... Drum brake
Front tire size ................................................................ 130/90-16 67H, tube or 30/90-16M/C 67H, tube
Rear tire size................................................................. 170/80-15M/C 77H, tube
Front fork stroke ............................................................ 140 mm (5.5 in)
Rear wheel travel .......................................................... 105 mm (4.1 in)
ELECTRICAL
Ignition type .................................................................. Electronic ignition (Transistorized)
Ignition timing................................................................ 5°B TD.C at 1 110 r/min
Spark plug..................................................................... NGK: DPR8EA-9 or DENSO: X24EPR-U9
Battery .......................................................................... 12 V 36 kC (10 Ah)/10HR
Generator..................................................................... Three-phase A.C. Generator
Main fuse ................................................................. 30 A
Fuse ...................................................................... .... 15/15/10/10/10/10 A
Headlight........................................................... ........ 12 V 60/55 W
Position/parking light.............................................. ..... 12 V 4 W........Except for E-03, 24, 28, 33
Front turn signal light ....................................... .......... 12 V 21 W.......... E-02, 19, 24
12 V 21/5 W....... E-03, 28, 33
Rear turn signal light................................. .... ............ 12 V 21 W
Brake light/Taillight........................... .......................... 12 V 21/5 W
Speedometer light......................... ......... .................... LED
Neutral indicator light................. . .............................. LED
High beam indicator light ........... .... ........................... LED
Turn signal indicator light.... ....... ............................... LED
Oil pressure light.......... ... ........................................... LED
CAPACITIES
Fuel tank ......... ...... .............................................. 17.0 L (4.5/3.7 US/lmp gal)
Engine oil, oil change ................................................... 3 000 ml (3.2/2.6 US/lmp qt)
with filter change......................................... 3 400 ml (3.6/3.0 US/lmp qt)
overhaul ...................................................... 3 700 ml (3.9/3.3 US/lmp qt)
Final gear oil ................................................................. 200 –220 ml (6.8/7.0 –7.4/7.7 US/lmp qt)
Engine coolant .............................................................. 1 500 ml (1.5/1.3 US/lmp qt)
Front fork oil (each leg) ................................................. 412 ml (13.9/14.5 US/lmp oz)
These specifications are subject to change without notice.

1-10 GENERAL INFORMATION
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA
E-02 England (UK)
E-03 USA
E-19 EU
E-24 Australia
E-28 Canada
E-33 California

PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
2

2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms
of kilometer, miles and months, whichever comes first.
IMPORTANT (USA only):
The periodic maintenance intervals and service requirements have been established in accordance with EPA
regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards
and it will also ensure the reliability and performance of the motorcycle. The chart below lists the recom-
mended intervals for all the required periodic service work necessary to keep the motorcycle operating at
peak performance and economy. Mileages are expressed in terms of kilometer, miles and time for your
convenience.
NOTES:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Air cleaner element - I I R I
Spark plugs - I R I R
Valve clearance I - I - I
Engine oil R RRRR
Engine oil filter R - - R -
Fuel line - I I I I
Replace fuel hose every 4 years.
Idle speed I I I I I
Evaporative emission control system - - I - I
(E-33 only) Replace vapor hose every 4 years.
PAIR (air supply) system - - I - I
Throttle cable play I I I I I
Clutch - I I I I
Radiator hoses - I I I I
Engine coolant Replace every 2 years.
Final gear oil R - I - I
Brakes I I I I I
Brake hoses - I I I I
Replace every 4 years.
Brake fluid - I I I I
Replace every 2 years.
Tires - I I I I
Steering I - I - I
Front forks - - I - I
Rear suspension - - I - I
Exhaust pipe bolts and muffler bolt and nut T - T - T
Chassis bolts and nuts T T T T T
I = Inspect and adjust, clean, lubricate or replace as necessary.
R = Replace
T = Tighten

PERIODIC MAINTENANCE 2-3
Clutch lever holder
Gearshift link pivot Side-stand pivot
and spring hook
Throttle cable Brake lever holder
Brake pedal pivot
and brake rod link
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially whenever the
motorcycle has been operated under wet or rainy conditions.

2-4 PERIODIC MAINTENANCE
MAINTENANCE ANDTUNE-UP
PROCEDURES
This section describes the servicing procedures for each item
mentioned in the Periodic Maintenance chart.
AIR CLEANER
• Remove the screws and air cleaner case cover.
• Remove the air cleaner element.
• Carefully use air hose to blow the dust from the cleaner ele-
ment.
NOTE:
Always apply air pressure on the engine side of the air cleaner
element. If air pressure is applied improperly, dirt will be forced
into the pores of the air cleaner element thus restricting air flow
through the air cleaner element.
• Reinstall the cleaned or new air cleaner element in the reverse
order of removal.
NOTE:
If driving under dusty conditions, clean the air cleaner element
more frequently. Make sure that the air cleaner is in good condi-
tion at all times. The life of the engine depends largely on this
component.
• Remove the drain plugs from the air cleaner box to allow any
water to drain out.
SPARK PLUG
SPARK PLUG AND IGNITION COIL/PLUG CAP REMOVAL
• Remove the front and rear seat. (!7-2)
• Remove the fuel tank. (!5-3)