Suzuki VLR1800 Service Manual

Name: Suzuki VLR1800
Brand: Suzuki
Rating: 5 (1 reviews)

624 pages

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1-iv Table of Contents

Ignition System Components Location................1H-1

Diagnostic Information and Procedures............1H-2

Ignition System Symptom Diagnosis...................1H-2

No Spark or Poor Spark......................................1H-3

Repair Instructions ..............................................1H-4

Ignition Coil / Plug Cap and Spark Plug Cap

Removal and Installation...................................1H-4

Ignition Coil Removal and Installation .................1H-5

Spark Plug Removal and Installation ..................1H-6

Spark Plug Inspection and Cleaning...................1H-6

Ignition Coil / Plug Cap / Ignition Coil

Inspection..........................................................1H-6

CKP Sensor Inspection .......................................1H-9

CKP Sensor Removal and Installation ..............1H-10

Engine Stop Switch Inspection..........................1H-10

Ignition Switch Inspection..................................1H-10

Ignition Switch Removal and Installation...........1H-10

Specifications.....................................................1H-11

Service Data......................................................1H-11

Tightening Torque Specifications......................1H-11

Special Tools and Equipment ...........................1H-11

Special Tool ......................................................1H-11

Starting System .........................................1I-1

Schematic and Routing Diagram......................... 1I-1

Starting System Diagram ..................................... 1I-1

Component Location ............................................ 1I-1

Starting System Components Location................ 1I-1

Diagnostic Information and Procedures............. 1I-1

Starting System Symptom Diagnosis................... 1I-1

Starter Motor will not Run..................................... 1I-2

Starter Motor Runs but Does not Crank the

Engine................................................................ 1I-2

Repair Instructions ............................................... 1I-3

Starter Motor Components................................... 1I-3

Starter Motor Removal and Installation................ 1I-4

Starter Motor Disassembly and Assembly ........... 1I-5

Starter Motor Inspection....................................... 1I-6

Starter Relay Removal and Installation................ 1I-7

Starter Relay Inspection....................................... 1I-7

Turn Signal / Side-stand Relay Removal and

Installation.......................................................... 1I-8

Side-stand / Ignition Interlock System Parts

Inspection........................................................... 1I-8

Starter Torque Limiter / Starter Clutch

Removal and Installation.................................. 1I-11

Starter Torque Limiter Inspection....................... 1I-12

Starter Clutch Inspection.................................... 1I-13

Starter Button Inspection.................................... 1I-13

Specifications...................................................... 1I-14

Service Data....................................................... 1I-14

Tightening Torque Specifications....................... 1I-14

Special Tools and Equipment ............................ 1I-15

Recommended Service Material ........................ 1I-15

Special Tool ....................................................... 1I-15

Charging System......................................1J-1

Schematic and Routing Diagram ........................ 1J-1

Charging System Diagram .................................. 1J-1

Component Location ........................................... 1J-1

Charging System Components Location............. 1J-1

Diagnostic Information and Procedures............ 1J-1

Charging System Symptom Diagnosis................ 1J-1

Battery Runs Down Quickly ................................ 1J-2

Repair Instructions .............................................. 1J-3

Battery Current Leakage Inspection.................... 1J-3

Regulated Voltage Inspection ............................. 1J-3

Generator Inspection........................................... 1J-4

Generator Removal and Installation.................... 1J-5

Regulator / Rectifier Inspection ........................... 1J-7

Battery Components ........................................... 1J-8

Battery Charging ................................................. 1J-8

Battery / Battery Holder Removal and

Installation ....................................................... 1J-11

Battery Visual Inspection................................... 1J-12

Specifications..................................................... 1J-13

Service Data...................................................... 1J-13

Tightening Torque Specifications...................... 1J-13

Special Tools and Equipment ........................... 1J-13

Recommended Service Material ....................... 1J-13

Special Tool ...................................................... 1J-13

Exhaust System....................................... 1K-1

Precautions...........................................................1K-1

Precautions for Exhaust System .........................1K-1

General Description .............................................1K-1

Exhaust Control System Description...................1K-1

Exhaust Control System Operation.....................1K-1

Repair Instructions ..............................................1K-2

Exhaust Control System Construction ................1K-2

Exhaust System Components.............................1K-3

EXCVA / EXCV Cable Removal and

Installation .........................................................1K-4

EXCVA Inspection...............................................1K-7

EXCVA Pulley / EXCV Cable Inspection.............1K-7

EXCVA Adjustment .............................................1K-7

Exhaust Pipe / Muffler Removal and

Installation .........................................................1K-9

Exhaust System Inspection...............................1K-12

EXCV Inspection ...............................................1K-12

Specifications.....................................................1K-13

Service Data......................................................1K-13

Tightening Torque Specifications......................1K-13

Special Tools and Equipment ...........................1K-13

Recommended Service Material .......................1K-13

Special Tool ......................................................1K-13

Questions and Answers:

J
Jeffrey HoldenJul 27, 2025
What to do if my Suzuki VLR1800 Motorcycle is difficult to start?
- M
  mitchellmichelleJul 27, 2025
  If your Suzuki Motorcycle is hard to start, begin by checking the battery condition. Also, inspect the vacuum hose for looseness, bends, and disconnections. Look for any broken fuses. Inspect for exhaust gas leakage and unusual noise, and check for any disconnected couplers.

Suzuki VLR1800 Specifications

General

Manufacturer	Suzuki
Model	VLR1800
Compression Ratio	10.5:1
Fuel System	Fuel injection
Starter	Electric
Transmission	5-speed
Category	Cruiser
Displacement	1783 cc
Ignition	Electronic ignition (Transistorized)
Final Drive	Shaft
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Rear Brakes	Single disc
Ground Clearance	140 mm
Seat Height	705 mm