Suzuki VL1500K5 - ENGINE INSTALLATION PROCEDURE

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VL1500K5 (’05-MODEL) 15

• Remove the PAIR device bracket



• Remove the No. 1 and No. 2 PAIR pipes.

• Remove the air cleaner box. (!Page 103)

• Remove the throttle body. (!Page 104)

SAMPLE

Main Page

Table of Contents2
Country and Area Codes3
Abbreviations Used in this Manual4
Specifications6
Periodic Maintenance Chart8
Periodic Maintenance Schedule8
- Fuel Hose9
- Engine Idle Speed9
Maintenance and Tune-Up Procedures9
- Throttle Cable Play10
- Throttle Valve Synchronization11
- Exhaust Pipe Bolts and Muffler Bolts12
- Chassis Bolts and Nuts13
Engine Components Removable with Engine in Place14
Engine Removal and Installation15
Engine Installation17
Engine Disassembly and Reassembly18
Engine Components Inspection and Servicing19
Precautions in Servicing20
Electrical Circuit Inspection Procedure23
Fi System Technical Features27
Injection Stop Control28
Fuel Delivery System29
Fi System Parts Location30
Fi System Wiring Diagram32
Ecm Terminal33
Self-Diagnosis Function34
- Dealer Mode35
- Tps Adjustment37
Fail-Safe Function38
Fi System Troubleshooting39
- Visual Inspection40
- Use of Sds Diagnostic Procedures42
- Show Data When Trouble44
- Displaing Data at the Time of Dtc44
- Malfunction Code and Defective Condition45
Fuel System94
- Fuel Pressure Inspection95
- Fuel Pump Inspection96
- Fuel Pump Relay Inspection97
- Fuel Pump Disassembly100
- Fuel Mesh Filter Inspection and Cleaning101
Throttle Body103
- Air Cleaner Box Removal104
- Throttle Body Removal105
- Throttle Body Disassembly106
- Throttle Body Cleaning108
- Throttle Body Reassembly109
- Throttle Body Installation111
- Stp Sensor Adjustment111
- Fuel Injector Removal112
- Fuel Injector Inspection112
- Fuel Injector Installation112
- Fast Idle113
- Fast Idle Adjustment113
Sensors119
- Ckp Sensor Inspection120
- Iat Sensor Inspection120
- To Sensor Inspection121
Exterior Parts122
Front Fork123
Removal and Disassembly124
Location of Electrical Components128
Charging System130
Automatic Decompression System/Starter System and Side-Stand Ignition Interlock System132
Ignition System134
Speedometer139
Relays142
Switches143
Battery144
Wiring Harness, Cable and Hose Routing145
- Front Brake Hose Routing149
- Rear Brake Hose Routing150
Exterior Parts Installation154
Brake Pedal Installation157
Special Tools158
Tightening Torque159
Service Data160
- Drive Train163
- Oil Pump163
- Battery165
- Headlight165
- Spark Plug165
- Brake Light/Taillight166
- High Beam Indicator Light166
- Neutral Indicator Light166
- Oil Pressure Indicator Light166
- Position/Parking Light166
- Speedometer Light166
- Turn Signal Indicator Light166
Tire Pressure167
Emission Control Systems169
- Crankcase Emission Control System170
- Noise Emission Control System172
Pair (Air Supply) System Inspection173
Pair (Air Supply) System Diagram175
Pair (Air Supply) System Hose Routing176
Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)177
Wiring Diagram178

Suzuki VL1500K5 - ENGINE INSTALLATION PROCEDURE

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