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Suzuki 2005 VL800 User Manual

Suzuki 2005 VL800
141 pages
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Table of Contents

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Suzuki 2005 VL800 Specifications

General IconGeneral
ManufacturerSuzuki
Year2005
ModelVL800
CategoryCruiser
Displacement805 cc
Bore x Stroke83.0 mm x 74.4 mm
Compression Ratio9.4:1
IgnitionElectronic ignition (transistorized)
LubricationWet sump
Transmission5-speed constant mesh
Final DriveShaft drive
Front SuspensionTelescopic, coil spring, oil damped
Front BrakesSingle disc
Rear BrakesDrum
Front Tire130/90-16
Rear Tire170/80-15
Seat Height700 mm (27.6 in)
Ground Clearance140 mm (5.5 in)
Engine Type4-stroke, SOHC
Rear SuspensionLink type, coil spring, oil damped
Overall Height1, 110 mm
Wheelbase1, 655 mm

Summary

Country and Area Codes

Specifications

Dimensions and Dry Mass

Detailed physical and weight specifications of the motorcycle.

Drive Train

Specifications related to the transmission, clutch, and drive system.

Chassis

Specifications for the frame, suspension, wheels, and steering.

Electrical

Specifications for ignition, charging system, lighting, and battery.

Capacities

Fluid capacities for engine oil, coolant, and fuel tank.

Abbreviations Used in This Manual

SAE-to-Former Suzuki Term

Periodic Maintenance Chart

Engine Idle Speed

Guidance on checking and adjusting engine idle speed.

Precautions in Servicing

Electrical Parts Connector/Coupler

Safe handling procedures for electrical connectors.

ECM/Various Sensors

Precautions for handling the ECM and various sensors.

Electrical Circuit Inspection Procedure

Open Circuit Check

Procedure for identifying open circuits in electrical systems.

Voltage Check

Steps for performing voltage checks on electrical circuits.

Using the Multi-Circuit Tester

Using the Tester

Instructions for operating the multi-circuit tester.

FI System Technical Features

Compensation of Injection Time (Volume)

How signals affect injection time and volume.

FI System Parts Location

FI System Wiring Diagram

Self-Diagnosis Function

User Mode

Using the self-diagnosis function in user mode.

Dealer Mode

Using dealer mode for self-diagnosis and malfunction codes.

Malfunction Code and Defective Condition

TPS Adjustment

Fail-Safe Function

Customer Complaint Analysis

Problem Symptoms

Categorization of common motorcycle operational problems.

Visual Inspection

Guidelines for visual checks of motorcycle components.

Self-Diagnostic Procedures

Self-Diagnosis Reset Procedure

Use of SDS Diagnostic Procedures

Procedures for using the SDS tool for diagnostics.

Show Data When Trouble (Displaying Data at the Time of DTC)

ECM Terminal

CKP Sensor Circuit Malfunction

Inspection

Step-by-step inspection procedures for the CKP sensor circuit.

IAP Sensor Circuit Malfunction

Inspection

Inspection steps for the IAP sensor circuit.

TP Sensor Circuit Malfunction

Inspection

Inspection procedures for the TP sensor circuit.

ECT Sensor Circuit Malfunction

Inspection

Inspection steps for the ECT sensor circuit.

IAT Sensor Circuit Malfunction

Inspection

Inspection procedures for the IAT sensor circuit.

TO Sensor Circuit Malfunction

Inspection

Inspection steps for the TO sensor circuit.

STV Actuator Circuit Malfunction

Inspection

Inspection procedures for the STV actuator circuit.

Active Control Inspection

Procedure for checking the active control function of the STVA.

STP Sensor Circuit Malfunction

Inspection

Inspection steps for the STP sensor circuit.

GP Switch Circuit Malfunction

Inspection

Inspection procedures for the GP switch circuit.

Fuel Injector Circuit Malfunction

Inspection

Inspection steps for the fuel injector circuit.

FP Relay Circuit Malfunction

Inspection

Inspection procedures for the fuel pump relay circuit.

PAIR Control Solenoid Valve Circuit Malfunction

Inspection

Inspection steps for the PAIR control solenoid valve circuit.

HO2 Sensor (HO2S) Circuit Malfunction

Inspection

Inspection steps for the HO2 sensor circuit.

Sensors

CKP Sensor Inspection

How to inspect the Crankshaft Position Sensor (CKP).

IAP Sensor Inspection

How to inspect the Intake Air Pressure Sensor (IAP).

TP Sensor Inspection

How to inspect the Throttle Position Sensor (TP).

ECT Sensor Inspection

How to inspect the Engine Coolant Temperature Sensor (ECT).

IAT Sensor Inspection

How to inspect the Intake Air Temperature Sensor (IAT).

STP Sensor Inspection

How to inspect the Secondary Throttle Position Sensor (STP).

Fuel Delivery System

Fuel System

Fuel Tank Removal

Procedures for safely removing the fuel tank.

Fuel Pressure Inspection

How to inspect fuel pressure using a gauge.

Fuel Pump Inspection

Procedures for inspecting the fuel pump operation.

Fuel Pump Construction

Fuel Pump Removal and Disassembly

Fuel Mesh Filter Inspection and Cleaning

How to inspect and clean the fuel mesh filter.

Fuel Pump Reassembly and Installation

Throttle Body Construction

Air Cleaner Box Removal

Throttle Body Removal

Throttle Body Disassembly

Throttle Body Cleaning

Throttle Body Reassembly

Throttle Body Installation

STP Sensor Adjustment

Fuel Injector Removal

Steps for removing the fuel injectors.

Fuel Injector Inspection

Fuel Injector Installation

Procedures for installing fuel injectors.

Fast Idle

Fast Idle Adjustment

Procedure to adjust the fast idle speed of the engine.

Throttle Valve Synchronization

Use of Digital Vacuum Tester

Steps to synchronize throttle valves using a digital vacuum tester.

Use of Vacuum Balancer Gauge

Procedure for calibrating and using a vacuum balancer gauge.

Throttle Position Sensor (TPS) Setting

Emission Control Systems

Fuel Injection System

Overview of the fuel injection system for emission control.

Exhaust Emission Control System (PAIR System)

Details on the PAIR system for exhaust emission control.

Evaporative Emission Control System (Only for E-33)

Specifics of the evaporative emission control system.

PAIR (Air Supply) System and Emission Control System Inspection

PAIR Reed Valve

Inspection and replacement of the PAIR reed valve.

PAIR Control Solenoid Valve

Inspection and testing of the PAIR control solenoid valve.

Evaporative Emission Control System Inspection (Only for E-33)

Hoses (EVAP Hose)

Inspection of EVAP hoses for wear or damage.

EVAP Canister

Inspection of the EVAP canister for damage.

Tightening Torque Chassis

Wiring Harness, Cable and Hose Routing

Wiring Harness Routing

Diagrams showing the routing of various wiring harnesses.

Cable Routing

Cooling System Hose Routing

Speed Sensor Lead Wire Routing

Fuel Tank Installation

Brake Pedal Installation

Handlebar Balancer

Information on the handlebar balancer assembly.

PAIR (Air Supply) System Diagram

PAIR (Air Supply) System Hose Routing

EVAP Canister Hose Routing (Only for E-33)

Special Tools

Wire Color

Wiring Diagram

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