Suzuki VZR1800 2007 User manual

VZR1800

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
DRIVELINE/AXLE 4
FI SYSTEM DIAGNOSIS 5
FUEL SYSTEM AND THROTTLE
BODY 6
EXHAUST SYSTEM7
COOLING AND LUBRICATION
SYSTEM8
CHASSIS9
ELECTRICAL SYSTEM 10
SERVICING INFORMATION 11
EMISSION CONTROL
INFORMATION 12
FOREWORD
This manual contains an introductory description on
the SUZUKI VZR1800 and procedures for its
inspection/service and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2006
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
99500-39293-03E

SUPPLEMENTS
VZR1800 ('07-MODEL)
VZR1800 ('08-MODEL)
13
14
15
VZR1800/NK9 (’09-MODEL) 16
VZR1800N ('08-MODEL)
WIRING DIAGRAM 17

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU 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 you find the item and page you need.
COMPONENT PARTS AND WORK TO 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
1Brake disc
2Dust seal
3Bearing
4Spacer
5Collar
6Front wheel
AFront axle
BBrake disc bolt
"
ITEM N·m
kgf-m lb-ft
A100 10.0 72.5
B23 2.3 16.5

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360” or
equivalent.
99000-32130
Apply oil.
Use engine oil unless otherwise speci-
fied.
Use engine coolant or equivalent.
99000-99032-11X
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Use fork oil or equivalent.
99000-99044-L01
Apply SUZUKI SUPER GREASE “A” or
equivalent.
99000-25010 Apply or use brake fluid.
Apply SUZUKI MOLY PASTE or equiva-
lent.
99000-25140 Measure in voltage range.
Apply SUZUKI SILICON GREASE or
equivalent.
99000-25100 Measure in current range.
Apply SUZUKI BOND “1215” or equiva-
lent.
99000-31110 Measure in resistance range.
Apply SUZUKI BOND “1207B” or equiv-
alent.
99000-31140 Measure in diode test range.
Apply THREAD LOCK SUPER “1303”
or equivalent.
99000-32030 Measure in continuity test range.
Apply THREAD LOCK SUPER “1322”
or equivalent.
99000-32110 Use special tool.
Apply THREAD LOCK “1342” or equiv-
alent.
99000-32050 Indication of service data.

ABBREVIATIONS USED IN THIS
MANUAL
AABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
A/F : Air Fuel Mixture
BBBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
CCKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU : Central Processing Unit
DDC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
EECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
EVAP : Evaporative Emission
EVAP Canister: Evaporative Emission
Canister (Canister)
EXC System : Exhaust Control System (EXCS)
EXC Valve : Exhaust Control Valve (EXCV)
EXCV Actuator : Exhaust Control Valve Actuator
(EXCVA)
FFI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
GGEN : Generator
GND : Ground
GP Switch : Gear Position Switch
HHC : Hydrocarbons
IIAP Sensor : Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Valve : Idle Speed Control Valve (ISCV)
LLCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
NNOX : Nitrogen Oxides

OOHC : Over Head Camshaft
OPS : Oil Pressure Switch
PPCV : Positive Crankcase
Ventilation (Crankcase Breather)
RRH : Right Hand
ROM : Read Only Memory
SSAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
STC System : Secondary Throttle Control System
(STCS)
STP Sensor : Secondary Throttle Position Sensor
(STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
TTO Sensor : Tip-Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)

SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAE TERM FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DLC Dealer Mode Coupler
Diagnostic Test Mode DTM ––––
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition El ––––
Engine Control Module ECM Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Coolant Level ECL Coolant Level
Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-
perature
Water Temperature
Engine Oil Temperature EOT Oil Temperature, Engine Oil Temperature
Engine Speed RPM Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister ––––(Canister)
Exhaust Control System EXCS EXC System (EXCS)
Exhaust Control Valve EXCV EXC Valve (EXCV)
Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA)
Purge Valve Purge Valve Purge Valve (SP Valve)
F
Fan Control FC ––––
Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)

SAE TERM FORMER SUZUKI TERM
FULL TERM ABBREVIATION
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
H
Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S), O2 Sensor
I
Idle Speed Control ISC ––––
Idle Speed Control Valve –––– ISC Valve
Ignition Control IC Electronic Spark Advance (ESA)
Ignition Control Module ICM ––––
Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera-
ture
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum
Mass Air Flow MAF Air Flow
O
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL ––––
P
ProgrammableRead OnlyMemory PROM ––––
Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR)
R
Random Access Memory RAM ––––
Read Only Memory ROM ROM
S
Secondary Air Injection AIR ––––
Secondary Throttle Control Sys-
tem STCS STC System (STCS)
Secondary Throttle Valve STV ST Valve (STV)
Secondary Throttle Valve Actuator STVA STV Actuator (STVA)
T
Throttle Body TB Throttle Body (TB)
Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)