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.