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Suzuki 2004 VL800 User Manual

Suzuki 2004 VL800
92 pages
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VL800
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OWNER'S MANUAL
This owner's manual contains
important safety information.
Plef3se read it carefully.
* SUZUKI
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Suzuki 2004 VL800 Specifications

General IconGeneral
ManufacturerSuzuki
ModelVL800
Year2004
Displacement805 cc
Bore x Stroke83.0 mm x 74.4 mm
Compression Ratio9.4:1
IgnitionElectronic ignition (transistorized)
Transmission5-speed constant mesh
Final DriveShaft drive
Front SuspensionTelescopic, coil spring, oil damped
Front BrakesSingle disc brake
Rear BrakesDrum brake
Front Tire130/90-16
Rear Tire170/80-15
Seat Height700 mm (27.6 in)
Ground Clearance140 mm (5.5 in)
Engine Type4-stroke, liquid-cooled, 45° V-twin
Rear Suspensionoil damped
Overall Width985 mm
Wheelbase1, 655 mm
Curb Weight246 kg
CategoryCruiser

Summary

Foreword

Important Safety Signal Words

Explains the meaning and usage of WARNING, CAUTION, and NOTE signal words in the manual.

The Sport of Motorcycling

Accident Avoidance and Defensive Riding

Emphasizes defensive riding, visibility, and awareness of other drivers to avoid accidents.

Helmet and Eye Protection

Stresses the importance of wearing a helmet and eye protection for safety.

Emergency Braking Techniques

Explains proper braking techniques, emphasizing the use of both front and rear brakes.

Rider Training Courses

Recommends practicing safety techniques through rider training courses like MSF.

Riding Within Your Limits

Advises riders to stay within their skill limits to avoid accidents.

Safe Riding Practices

Highlights mental and physical readiness, avoiding alcohol/drugs, and riding cautiously.

Riding in Bad Weather

Provides advice for riding in adverse weather conditions like rain, emphasizing caution.

Carrying a Passenger Safely

Offers guidance on safely carrying a passenger, including adjustments and precautions.

Street Smart Riding

Encourages riders to obey laws, speed limits, and maintain a courteous attitude.

Fuel, Oil and Coolant Recommendations

Fuel Requirements

Details the type of unleaded gasoline and octane rating required for the motorcycle.

Fuel Blends and Additives

Explains the use of oxygenated fuels, MTBE, ethanol, and methanol blends, and their limitations.

Engine Oil Specifications

Recommends specific SUZUKI PERFORMANCE MOTOR OIL or equivalent, and viscosity grades.

Gear Oil Specifications

Specifies the use of SAE90 hypoid gear oil (GL-5) or SAE80 for cold temperatures.

Engine Coolant Requirements

Details the 50:50 mixture of engine coolant and distilled water for the cooling system.

Location of Labels

Motorcycle Safety Labels

Advises to read and understand all safety labels on the motorcycle and not to remove them.

General Safety Warnings

Warns about risks of injury if safety precautions and manual instructions are not followed.

Importance of Owner's Manual

Stresses the importance of reading the manual for safety and operational instructions.

Location of Parts

Handlebar Controls and Components

Identifies key components located on the left and right handlebars and the front of the motorcycle.

Main Motorcycle Components

Identifies various parts of the motorcycle, including levers, stands, and holders.

Additional Motorcycle Components

Identifies additional components such as air cleaner, ignition switch, and brake pedal.

Controls, Equipment and Adjustments

Key and Ignition Switch Operation

Explains key usage and ignition switch positions (OFF, ON, LOCK).

Parking Position and Steering Lock

Details the parking position of the ignition switch and how to lock the steering.

Instrument Panel Overview

Describes speedometer, odometer, trip meters, and fuel meter functions.

Clock Adjustment Procedure

Provides steps to set the 12-hour clock display on the instrument panel.

Odometer, Trip Meters, and Turn Signal Indicator

Explains odometer/trip meter functions and the turn signal indicator light.

Neutral, Oil Pressure, and Other Indicator Lights

Covers neutral, oil pressure, high beam, and coolant temperature indicators.

Left Handlebar Controls

Details clutch, headlight, turn signals, and horn controls.

Right Handlebar Controls

Describes engine stop switch and front brake lever, including adjustment.

Hazard Lights, Starter, and Throttle Grip

Explains hazard lights, starter button, and throttle grip operation.

Fuel Tank Cap Operation

Instructions for opening/closing fuel cap, with overfilling warnings.

Choke Knob and Gearshift Lever

Explains choke usage for starting and the 5-speed gearshift operation.

Rear Brake Pedal and Helmet Holder

Details rear brake pedal operation and how to use the helmet holder.

Side Stand and Interlock System

Explains side stand operation and its interlock system.

Rear Suspension Adjustment

Guides on adjusting rear suspension spring pre-load for different conditions.

Break-In

Importance of Break-In Period

Emphasizes the critical nature of the first 800 km for motorcycle longevity and performance.

Maximum Throttle Opening Limits

Provides a table with recommended maximum throttle openings during the break-in period.

Varying Engine Speed During Break-in

Advises varying engine speed during break-in to aid component mating and cooling.

New Tire Break-In Procedure

Guides on breaking in new tires by gradually increasing lean angles and avoiding harsh maneuvers.

Initial Service (1000 km Maintenance)

Highlights the importance of the initial 1000 km service for adjustments and fastener tightening.

Inspection Before Riding

Pre-Ride Inspection Importance

Stresses the critical need for pre-ride inspections to prevent accidents and equipment damage.

Performing Pre-Ride Checks

Instructs to always perform a thorough pre-ride inspection before operating the motorcycle.

Pre-Ride Inspection Checklist

Lists essential items to check before riding for safety and reliability.

Tire Condition Check

Warns about the dangers of worn, improperly inflated, or incorrect tires affecting stability.

Riding Tips

Starting the Engine Procedure

Provides detailed steps for starting the engine, including cold and warm conditions and interlock checks.

Engine Starting Scenarios

Offers advice for starting a warm engine and troubleshooting a hard-to-start engine.

Starting Off and Shifting Gears

Guides on safely starting from a stop and shifting through gears while riding.

Using the Transmission Effectively

Explains how to use the transmission for smooth operation and provides shifting speed guidelines.

Riding on Hills

Advises on shifting gears for climbing and descending hills to maintain power and control.

Stopping and Parking Procedures

Details the correct procedure for stopping the motorcycle and selecting neutral.

Carrying a Passenger Safely

Provides instructions for carrying a passenger, including adjustments and passenger behavior.

Accessory Use and Motorcycle Loading

General Accessory Usage Guidelines

Warns against unsuitable accessories and advises consulting dealers for selection and installation.

Accessory Installation Best Practices

Provides guidelines for installing accessories, focusing on aerodynamics, mounting, and clearance.

Cargo Loading Guidelines

Offers advice on balancing loads, placement, and securing items to maintain motorcycle control.

Maximum Loading Limits

Specifies the combined weight limits for rider, passenger, gear, and cargo to ensure safe operation.

Modification

Consequences of Modification

Warns that modifying the motorcycle or removing original parts can make it unsafe or illegal.

Inspection and Maintenance

Emission Control Device Maintenance Notice

States that emission control device maintenance can be performed by certified repair establishments.

Maintenance Schedule Overview

Emphasizes the importance of regular inspection and maintenance according to the schedule.

Detailed Maintenance Chart

Provides a chart detailing inspection, replacement, and tightening intervals for various motorcycle elements.

Tools

Included Tool Kit

Mentions that a tool kit is provided and its location in the toolbox.

General Lubrication

Importance of Lubrication

Explains that proper lubrication is vital for safe operation and longevity, increasing frequency in severe conditions.

Lubrication Points Identification

Illustrates and labels key points requiring lubrication with oil or grease.

Battery

Battery Type and Charging

Describes the sealed battery type and its standard/maximum charging rates.

Battery Safety Warnings

Warns about lead content, lead compounds, and explosive hydrogen gas produced by batteries.

Battery Removal Procedure

Provides step-by-step instructions for safely removing the motorcycle battery.

Air Cleaner

Air Cleaner Element Importance

Stresses keeping the air cleaner element clean for engine power and fuel economy, especially in dusty conditions.

Air Cleaner Element Removal

Details the steps for removing the air cleaner element for inspection and cleaning.

Air Cleaner Drain Plug

Explains the location and periodic maintenance for the air cleaner drain plug.

Spark Plug

Recommended Spark Plug Types

Lists the standard spark plug types and advises consulting a dealer if the insulator color is incorrect.

Spark Plug Cleaning and Gapping

Provides instructions for cleaning carbon deposits and adjusting the spark plug gap for optimal ignition.

Spark Plug Installation

Guides on safely installing new or used spark plugs, warning against crossthreading or overtightening.

Engine Oil

Engine Oil Importance

Highlights that engine oil amount and quality are critical for daily checks and periodic changes.

Engine Oil Level Check Procedure

Details the steps to check the engine oil level using the inspection window.

Engine Oil and Filter Change

Provides a step-by-step guide for changing the engine oil and oil filter, including draining and refilling.

Carburetor Adjustments

Explains idle speed adjustment and throttle cable play adjustments for the carburetor.

Fuel Hose

Fuel Hose Inspection

Advises inspecting the fuel hose for damage and leakage, and replacing if defects are found.

Clutch Adjustment

Clutch Cable Play Adjustment

Details minor and major adjustment procedures for clutch cable play to ensure proper operation.

Engine Coolant

Engine Coolant Level Check

Explains how to check the engine coolant level in the reservoir and add coolant if needed.

Final Gear Oil Change Procedure

Provides steps for changing the final gear oil, including draining and refilling with the correct type.

Brakes

Brake System Overview

Introduces the motorcycle's braking system, consisting of front disc and rear drum brakes.

Brake System Maintenance Importance

Stresses the importance of inspecting and maintaining brakes to prevent accidents.

Front Brake Fluid Level Check

Details how to check the front brake fluid level and the type of fluid to use, with safety warnings.

Brake Pad Wear Inspection

Guides on inspecting front brake pad wear and the procedure for replacing worn pads.

Rear Brake Pedal Adjustment

Explains how to adjust the rear brake pedal position and free travel for proper operation.

Rear Brake Lining Wear Check

Describes how to check the brake lining wear limit indicator on the rear brake.

Tires

Tire Safety Warnings

Warns about potential accidents due to tire failure and emphasizes critical tire maintenance.

Tire Pressure and Loading Guidelines

Provides guidelines for checking tire pressure and loading limits to ensure safe motorcycle control.

Tire Condition and Type Specifications

Advises on checking tire condition, wear limits, and using the specified tire size and type.

Rear Brake Light Switch

Rear Brake Light Switch Adjustment

Explains how to adjust the rear brake light switch for proper operation.

Light Bulb Replacement

Bulb Wattage Specifications

Lists the wattage ratings for various motorcycle bulbs and advises using the same rating for replacement.

Headlight Bulb Replacement

Provides instructions for removing and replacing the headlight bulb, including cautions about handling.

Turn Signal Bulb Replacement

Details the procedure for removing and replacing the turn signal light bulb.

Brake Light/Taillight Bulb Replacement

Explains how to remove and replace the brake light and taillight bulbs.

Fuses

Main Fuse Location

Indicates that the main fuse is located under the front seat and describes how to access it.

Fuse Locations and Types

Explains the location of fuses behind the left crankcase cover and lists spare fuse ratings.

Fuse Function List

Lists the amperage and function of each fuse in the electrical system.

Troubleshooting

Troubleshooting Guide Introduction

Introduces the troubleshooting section for common motorcycle complaints.

Engine Start Problems

Addresses issues where the engine is hard to start or won't start at all, pointing to fuel or ignition systems.

Fuel System Troubleshooting

Provides steps to check the fuel tank, fuel valve, and carburetor for starting issues.

Ignition System Troubleshooting

Details how to perform a spark test to diagnose ignition system problems.

Engine Stalling Issues

Lists possible causes for engine stalling, including fuel, spark plug, and idle speed issues.

Storage Procedure

Motorcycle Cleaning for Storage

Advises on cleaning the entire motorcycle before storing it for an extended period.

Fuel Preparation for Storage

Guides on filling the fuel tank with stabilized gasoline and draining the carburetor for long-term storage.

Engine Preparation for Storage

Explains how to prepare the engine by adding oil to spark plug holes and draining old oil.

Battery Preparation for Storage

Details the steps for removing and storing the battery to maintain its condition.

Tire Preparation for Storage

Advises inflating tires to normal specifications before storage.

Returning Motorcycle to Service

Outlines the steps to take the motorcycle out of storage and prepare it for riding.

Appearance Care

Corrosion Prevention Strategies

Provides information on causes of corrosion and methods to prevent it, like frequent washing and drying.

Motorcycle Washing Procedure

Details the steps for washing the motorcycle, including removing dirt and using mild detergent.

Motorcycle Waxing Recommendation

Recommends waxing the motorcycle after washing to protect and beautify the paint.

Post-Cleaning Inspection

Advises performing inspections after cleaning and lubricating according to the general lubrication section.

Consumer Information

Emission Control Warranty Details

Explains the emission control warranty coverage, useful life, and conditions.

Noise Control System Tampering Prohibition

Outlines federal laws prohibiting tampering with noise control systems on vehicles.

Frame and Engine Serial Number Location

Shows where to find the frame and engine serial numbers, essential for registration and parts ordering.

Reporting Safety Defects

Instructs owners on how to report potential safety defects to NHTSA and American Suzuki.

Specifications

Dimensions and Dry Mass Specifications

Lists the physical dimensions and dry mass of the motorcycle.

Engine Specifications

Details engine type, bore, stroke, displacement, compression ratio, and carburetor.

Drive Train Specifications

Provides specifications for the clutch, transmission, gear ratios, and drive system.

Chassis Specifications

Lists specifications for front and rear suspension, steering angle, caster, trail, and brakes.

Electrical System Specifications

Details ignition type, battery, generator, fuses, and bulb specifications.

Fluid Capacities

Lists the capacities for fuel tank, engine oil, final gear oil, and engine coolant.

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