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CMYK

Suzuki Red0

1001000

Suzuki Blue1007000

takumi color1000085

Black000

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M 70%

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99011-43H50-03A

VL

800/C/T

Part No. 99011-43H50-03A August, 2008 EN Printed in Japan

WARNINGFailure to follow these safetyprecautions may increase yourrisk of injury:

Wear a helmet, eye protec-tion, and bright protectiveclothing.Don’t ride after consumingalcohol or other drugs.Slow down on slippery sur-faces, unfamiliar terrain, orwhen visibility is reduced.Read owner’s manual care-fully.

VL800/C/ TOWNER’S MANUALThis owner’s manual containsimportant safety information.Please read it carefully.

TK

K9

4 mm

No.825 VL800/C/T (99011-43H50-03A)

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4/1 ( /Black)

4 mm

No.825 VL800/C/T (99011-43H50-03A)

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

California Proposition 65 Warning

WARNINGEngine exhaust, some of its constituents, and certain product com-ponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

IMPORTANT

WARNING/CAUTION/NOTEPlease read this manual and fol-low its instructions carefully. Toemphasize special information,the symbol and the wordsWARNING, CAUTION and NOTEhave special meanings. Pay spe-cial attention to the messageshighlighted by these signal words:

NOTE: Indicates special informa-tion to make maintenance easieror instructions clearer.

WARNINGs and CAUTIONs arearranged like this:

FOREWORD

Motorcycling is one of the mostexhilarating sports and to ensureyour riding enjoyment, you shouldbecome thoroughly familiar withthe information presented in thisOwner’s Manual before riding themotorcycle.

The proper care and maintenancethat your motorcycle requires isoutlined in this manual. By follow-ing these instructions explicitlyyou will ensure a long trouble-freeoperating life for your motorcycle.This motorcycle also conforms tothe U.S Environmental ProtectionAgency emission regulationswhich apply to new motorcycles.The proper adjustment of enginecomponents is necessary for thismotorcycle to comply with theEPA regulations. Therefore,please follow the maintenanceinstructions closely to ensureemission compliance. Your autho-rized Suzuki dealer has experi-enced technicians that are trainedto provide your machine with thebest possible service with theright tools and equipment.

WARNINGIndicates a potential hazardthat could result in death orinjury.

CAUTIONIndicates a potential hazardthat could result in motorcycledamage.

WARNING-or-CAUTIONThe first part will describe aPOTENTIAL HAZARD andWHAT CAN HAPPEN if youignore the WARNING or CAU-TION.

The second part will describeHOW TO AVOID THE HAZARD.

All information, illustrations, andspecifications contained in thismanual are based on the latestproduct information available atthe time of publication. Due toimprovements or other changes,there may be some discrepan-cies between information in thismanual and your motorcycle.Suzuki reserves the right to makeproduction changes at any time,without notice and without incur-ring any obligation to make thesame or similar changes to vehi-cles previously built or sold.

Suzuki Motor Corporationbelieves in conservation and pro-tection of Earth’s Naturalresources. To that end, weencourage every vehicle owner torecycle, trade in, or properly dis-pose of, as appropriate, usedmotor oil, engine coolant, andother fluids, batteries, and tires.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2008

TABLE OF CONTENTS

1

2

3

4

5

6

7

8

9

10

THE SPORT OF MOTORCYCLING

FUEL, OIL AND COOLANT RECOMMENDATIONS

CONTROLS, EQUIPMENT AND ADJUSTMENTS

BREAK-IN AND INSPECTION BEFORE RIDING

RIDING TIPS

ACCESSORY USE AND MOTORCYCLE LOADING

INSPECTION AND MAINTENANCE

TROUBLESHOOTING

STORAGE PROCEDURE AND MOTORCYCLE CLEANING

CONSUMER INFORMATION

SPECIFICATIONS

INDEX

1-1

1


MOST ACCIDENTS CAN BE AVOIDED ............................................................. 1-2IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE ..................................................................... 1-3IF A COLLISION IS IMMINENT, DO SOMETHING! ........................................... 1-3SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......................................... 1-4KNOW YOUR LIMITS .......................................................................................... 1-4BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS ........................ 1-5PRACTICE AWAY FROM TRAFFIC ................................................................... 1-5INSPECTION BEFORE RIDING .......................................................................... 1-5ACCESSORIES AND LOADING ......................................................................... 1-5CARRYING A PASSENGER ............................................................................... 1-6MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA) ..................................................................................... 1-6BE STREET SMART ........................................................................................... 1-6CONCLUSION ..................................................................................................... 1-6

1-2


Your motorcycle and this owner’smanual have been designed bypeople like you who enjoy motor-cycling. People become motorcy-clists for many reasons. Forstarters, street riding is fun andinvigorating. But no matter whyyou became a motorcyclist, orhow experienced you are, you willeventually face some challengingsituations.

In preparing for these challenges,you will be fine-tuning your coordi-nation, concentration, and atti-tude. Learning the skills andstrategies associated with motor-cycling is the basis for safely par-ticipating in this sport. Manymotorcyclists find that as theybecome better riders, they alsoget more enjoyment from the free-dom unique to motorcycling.

Please remember:

MOST ACCIDENTS CAN BE AVOIDEDThe most common type of motor-cycle accident in the U.S. occurswhen a car traveling toward amotorcycle turns left in front of themotorcycle. Is that because otherdrivers are out to get motorcy-clists? No. Other drivers simplydon’t always notice motorcyclists.Ride defensively. Wise motorcy-clists use a strategy of assumingthey are invisible to other drivers,even in broad daylight. Pay care-ful attention to other motorists,especially at intersections,because they may not be payingattention to you. Select a laneposition that gives you the bestview of others, and other motor-ists the best view of you. Wearbright, reflective clothing. Putreflective strips on your helmet.

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IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDEMost accidents occur within a fewmiles of home, and almost halfoccur at speeds of less than 30mph. So even if you’re just goingon a quick errand, be prepared-strap on your helmet before youtake off.

Helmets do not reduce essentialvision or hearing. Generally, hel-mets do not cause or intensifyinjury if you crash. Helmets simplyhelp your skull protect your intelli-gence, your memory, your per-sonality, and your life.

Your eyesight is equally valuable.Wearing suitable eye protectioncan help keep your visionunblurred by the wind and saveyour eyes from airborne hazardslike bugs, dirt, or pebbles kickedup by tires.

IF A COLLISION IS IMMINENT, DO SOMETHING!Many riders fear locking up theirbrakes or haven’t learned toswerve to avoid an accident.Many inexperienced riders (andtoo many seasoned riders) useonly their rear brake in an emer-gency, resulting in unnecessaryimpacts in some cases andunnecessarily high impact speedsin other cases. Your rear brakecan only provide about 30% ofyour motorcycle’s potential stop-ping power. The front and rearbrakes can and should be usedtogether to maximize brakingeffectiveness.

Experienced motorcyclists learnto “cover” the front brake lever bylightly resting a couple of fingersover the lever when riding in trafficand near intersections to givetheir reaction time a head start.

1-4

Emergency stopping and swerv-ing are techniques that youshould practice and master beforeyou find yourself in an emergencysituation. The best place to prac-tice such techniques is in a con-trolled environment such as theMotorcycle Safety Foundation’s(MSF) rider training courses. TheMSF’s Motorcycle Rider Courses(fundamental techniques) andExperienced Rider Courses(advanced strategies) presenthands-on instruction of the basicprinciples of motorcycling and avariety of accident avoidancemaneuvers. Even a seasonedmotorcyclist can improve his orher riding skills, and pick up a fewnew skills, through these courses.Some insurance companies evenoffer discounts to course gradu-ates.

SPECIAL SITUATIONS REQUIRE SPECIAL CAREOf course, there are some timeswhen full-force braking is not thecorrect technique. When the roadsurface is wet, loose, or rough,you should brake with care. Whenyou’re leaned over in a corner,avoid braking. Straighten upbefore braking. Better yet, slowdown before entering a corner.

In these situations, the tractionavailable between your tires andthe road surface is limited. Over-braking when traction is limitedwill cause your tires to skid, possi-bly resulting in loss of directionalcontrol or causing you and yourmotorcycle to fall over.

KNOW YOUR LIMITSAlways ride within the boundariesof your own skills. Knowing theselimits and staying within them willhelp you avoid accidents.

A major cause of accidents involv-ing only a motorcycle (and nocars) is going too fast through aturn. Before entering a turn, selectan appropriately low corneringspeed.

Even on straight roads, ride at aspeed that is appropriate for thetraffic, visibility and road condi-tions, your motorcycle, and yourexperience.

1-5

Riding a motorcycle safelyrequires that your mental andphysical skills are fully part of theexperience. You should notattempt to operate a motor vehi-cle, especially one with twowheels, if you are tired or underthe influence of alcohol or otherdrugs. Alcohol, illegal drugs, andeven some prescription and over-the-counter drugs can causedrowsiness, loss of coordination,loss of balance, and especiallythe loss of good judgment. If youare tired or under the influence ofalcohol or other drugs, PLEASEDO NOT RIDE your motorcycle.

BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYSRiding on bad weather days,especially wet ones, requiresextra caution. Braking distancesincrease on a rainy day. Stay offthe painted surface marks, man-hole covers, and greasy appear-ing areas, as they can beespecially slippery. Use extra cau-tion at railway crossings and onmetal gratings and bridges. Whenit starts to rain, any oil or greaseon the road rises to the surface ofthe water. Pull over and wait a fewminutes until this oil film iswashed away before riding.Whenever in doubt about roadconditions, slow down!

PRACTICE AWAY FROM TRAFFICYour riding skill and your mechan-ical knowledge form the founda-tion for safe riding practices. Wesuggest that you practice ridingyour motorcycle in a nontraffic sit-uation until you are thoroughlyfamiliar with your machine and itscontrols. Again, consider takingone of the MSF’s Rider Courses.Even experts will be pleased withthe caliber of the information pre-sented in these courses. As theMSF says: “The more you know,the better it gets!”

INSPECTION BEFORE RIDINGReview the instructions in theINSPECTION BEFORE RIDINGsection of this manual. Perform anentire pre-ride inspection beforeyou head out on the road. Spend-ing a few minutes preparing yourmachine for a ride can help pre-vent accidents due to mechanicalfailure or costly, inconvenientbreakdowns far from home.

ACCESSORIES AND LOADINGThe accessories you use withyour motorcycle and the mannerin which you load your gear ontothe bike might create hazards.Aerodynamics, handling, balance,and cornering clearance can suf-fer, and the suspension and tirescan be overloaded. Read theACCESSORY USE ANDMOTORCYCLE LOADING sec-tion.

1-6

CARRYING A PASSENGERCarrying a passenger, when donecorrectly, is a great way to sharethe joy of motorcycling. You willhave to alter your riding stylesomewhat since the extra weightof a passenger will affect handlingand braking. You may also needto adjust tire pressures and sus-pension; please refer to the TirePressure and Loading sectionand the Suspension section formore details.

A passenger needs the same pro-tection that you do, including ahelmet and proper clothing. Thepassenger should not wear longshoe laces or loose pants thatcould get caught in the wheel orthe chain. Passengers must betall enough that their feet reachthe footrests.

MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA)This special handbook, suppliedwith your owner’s manual, con-tains a variety of safety tips, help-ful hints, and practice exercises.This manual can increase yourriding enjoyment and safety. Youshould read it thoroughly.

BE STREET SMARTAlways heed speed limits, locallaws, and the basic rules of theroad. Set a good example for oth-ers by demonstrating a courteousattitude and a responsible ridingstyle.

CONCLUSIONTraffic, road and weather condi-tions vary. Other motorist’sactions are unpredictable. Yourmotorcycle’s condition canchange. These factors can bestbe dealt with by giving every rideyour full attention.

Circumstances beyond your con-trol could lead to an accident. Youneed to prepare for the unex-pected by wearing a helmet andother protective gear, and learn-ing emergency braking andswerving techniques to minimizethe damage to you and yourmachine.

The best way to learn basic ridingskills and evasive maneuvers orrefresh your own riding skills is totake one of the courses offered bythe Motorcycle Safety Foundation.Your authorized Suzuki dealercan help you locate the funda-mental or advanced riding skillscourse nearest you, or owners inthe USA can call toll-free 1-800-446-9227.

Good riding on your new Suzuki!

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2


FUEL .................................................................................................................... 2-2ENGINE OIL ......................................................................................................... 2-3GEAR OIL ............................................................................................................ 2-4ENGINE COOLANT SOLUTION ......................................................................... 2-5

2-2


FUELYour motorcycle requires regularunleaded gasoline with a mini-mum pump octane rating of 87((R+M)/2 method). In some areas,the only fuels that are availableare oxygenated fuels.

Oxygenated fuels which meet theminimum octane requirement andthe requirements described belowmay be used in your motorcyclewithout jeopardizing the NewVehicle Limited Warranty or theEmission Control System War-ranty.

NOTE: Oxygenated fuels arefuels which contain oxygen-carry-ing additives such as MTBE oralcohol.

Gasoline containing MTBEUnleaded gasoline containingMTBE (Methyl Tertiary ButylEther) may be used in your motor-cycle if the MTBE content is notgreater than 15%. This oxygen-ated fuel does not contain alco-hol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline andethanol (grain alcohol), alsoknown as “GASOHOL”, may beused in your vehicle if the ethanolcontent is not greater than 10%.

Gasoline/Methanol BlendsFuels containing 5% or less meth-anol (wood alcohol) may be suit-able for use in your motorcycle ifthey contain co-solvents and cor-rosion inhibitors.

DO NOT USE fuels containingmore than 5% methanol underany circumstances. Fuel systemdamage or motorcycle perfor-mance problems resulting fromthe use of such fuels are not theresponsibility of Suzuki and maynot be covered under the NewVehicle Limited Warranty or theEmission Control System War-ranty.

Fuel Pump LabelingIn some states, pumps that dis-pense oxygenated fuels arerequired to be labeled for the typeand percentage of oxygenate, andwhether important additives arepresent. Such labels may provideenough information for you todetermine if a particular blend offuel meets the requirements listedabove. In other states, pumpsmay not be clearly labeled as tothe content or type of oxygenateand additives. If you are not surethat the fuel you intend to usemeets these requirements, checkwith the service station operatoror the fuel supplier.

2-3

NOTE: • To help minimize air pollution,

Suzuki recommends that youuse oxygenated fuels.

• Be sure that any oxygenatedfuel you use has octane rat-ings of at least 87 pumpoctane ((R+M)/2 method).

• If you are not satisfied with thedriveability of your motorcyclewhen you are using an oxy-genated fuel, or if engine ping-ing is experienced, substituteanother brand as there are dif-ferences between brands.

ENGINE OILOil quality is a major contributor toyour engine’s performance andlife. Always select good qualityengine oil. Suzuki recommendsthe use of SUZUKI PERFOR-MANCE 4 MOTOR OIL or equiva-lent engine oil. Use oil with an API(American Petroleum Institute)classification of SF/SG or SH/SJ,or with a JASO classification ofMA.

API: American Petroleum InstituteJASO: Japanese AutomobileStandards Organization

SAE Engine Oil ViscositySuzuki recommends the use ofSAE 10W-40 engine oil. If SAE10W-40 engine oil is not available,select an alternative according tothe following chart.

CAUTIONSpilled gasoline containingalcohol can harm your motor-cycle. Alcohol can damagepainted surfaces.

Be careful not to spill any fuelwhen filling the fuel tank. Wipespilled gasoline up immedi-ately.

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

2-4

JASO T903The JASO T903 standard is anindex to select engine oils for 4-stroke motorcycle and ATVengines. Motorcycle and ATVengines lubricate clutch andtransmission gears with engineoil. JASO T903 specifies perfor-mance requirements for motorcy-cle and ATV clutches andtransmissions.

There are two classes, MA andMB. The oil container shows theclassification as follows.

1 Code number of oil sales company2 Oil classification

Energy ConservingSuzuki does not recommend theuse of “ENERGY CONSERVING”oils. Some engine oils which havean API classification of SH orhigher have an “ENERGY CON-SERVING” indication in the APIclassification doughnut mark.These oils can affect engine lifeand clutch performance.

Not recommended Recommended

GEAR OILUse an SAE90 hypoid gear oilwhich is rated GL-5 under the APIclassification system. If you oper-ate the motorcycle where ambienttemperature is below 0°C (32°F),use SAE80 hypoid gear oil.

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

API SERVICE SJ

SAE10W-40

2-5

ENGINE COOLANT SOLUTIONUse engine coolant that is com-patible with an aluminum radiator,mixed with distilled water at a50:50 mixture ratio for enginecoolant solution. An engine cool-ant mixture other than 50:50 canaffect cooling efficiency or rustinhibiting performance.

Engine CoolantEngine coolant should be used atall times in your motorcycle’s radi-ator, even if the temperature inyour area does not go down to thefreezing point. Engine coolantacts as a rust inhibitor and waterpump lubricant as well as an anti-freeze solution.

Water for MixingUse distilled water only. Waterother than distilled water can cor-rode and clog the aluminum radia-tor.

Required amount of engine cool-ant/water solution capacity (total):1500 ml (3.2 US pt)

WARNINGEngine coolant is harmful orfatal if swallowed or inhaled.

Do not drink antifreeze or cool-ant solution. If swallowed, donot induce vomiting. Immedi-ately contact a poison controlcenter or a physician. Avoidinhaling mist or hot vapors; ifinhaled, remove to fresh air. Ifcoolant gets in eyes, flush eyeswith water and seek medicalattention. Wash thoroughlyafter handling. Solution can bepoisonous to animals. Keepout of the reach of children andanimals.

CAUTIONSpilled engine coolant candamage painted surfaces.

Do not spill any fluid when fill-ing the radiator. Wipe spilledengine coolant up immediately.

Engine coolant 750 ml(1.6 US pt)

Water 750 ml(1.6 US pt)

3-1

3


LOCATION OF PARTS ....................................................................................... 3-2KEY ...................................................................................................................... 3-5IGNITION SWITCH .............................................................................................. 3-5INSTRUMENT PANEL ......................................................................................... 3-7LEFT HANDLEBAR ........................................................................................... 3-13RIGHT HANDLEBAR ........................................................................................ 3-15FUEL TANK CAP .............................................................................................. 3-17GEARSHIFT LEVER .......................................................................................... 3-18REAR BRAKE PEDAL ...................................................................................... 3-18HELMET HOLDER ............................................................................................ 3-19SIDE STAND ...................................................................................................... 3-19SUSPENSION ADJUSTMENT .......................................................................... 3-20

3-2


LOCATION OF PARTS

1Clutch lever2Left handlebar switches3 Instrument panel4Front brake fluid reservoir5Right handlebar switches6Throttle grip7Front brake lever8Fuel tank cap

3-3

VL800

9Spark plugs0Battery and main fuseAToolsBHelmet holderCGearshift leverDFootrestsEEngine coolant reservoirFSide standGFusesHPassenger footrests

VL800C

VL800T

3-4

VL800

IAir cleanerJ Ignition switchKEngine oil filler capLEngine oil inspection windowMEngine oil drain plugNEngine oil filterORear brake light switchPRear brake pedal VL800C

VL800T

3-5

KEY

Two keys come with this motorcy-cle. Keep the spare key in a safeplace. An identifying number isstamped on the plate. Use thisnumber when making a replace-ment key.

Please write down your key num-ber in the box provided for yourfuture reference.

IGNITION SWITCH

The ignition switch has 4 posi-tions.

“OFF” positionAll electrical circuits are cut off.The engine will not start. The keycan be removed.

“ON” positionThe ignition circuit is completedand the engine can be started.The headlight, front turn signallight and taillight will automaticallyturn on. The key cannot beremoved in this position.

NOTE: Start the engine promptlyafter turning the key to the “ON”position, or the battery will losepower due to consumption by theheadlight and taillight.

“LOCK” positionAll electrical circuits are off. Thekey can be removed and thesteering will be locked. Turn thesteering all the way to the left andpush down the key and turn it tothe “LOCK” position.

Key number:

3-6

“P” (PARKING) positionThe taillight will come on toincrease visibility for temporaryroad side parking at night. Thekey can be removed and thesteering will be locked.

The key hole can be covered byturning the lid.

WARNINGTurning the ignition switch tothe “P” (PARKING) or “LOCK”position while the motorcycleis moving can be hazardous.Moving the motorcycle whilethe steering is locked can behazardous. You could lose yourbalance and fall, or you coulddrop the motorcycle.

Stop the motorcycle and placeit on the side stand before lock-ing the steering. Never attemptto move the motorcycle whenthe steering is locked.

3-7

Align the lid hole position with thekey hole position when insertingthe key.

INSTRUMENT PANEL

SPEEDOMETER 1The speedometer indicates theroad speed in kilometers per hourand miles per hour.

TURN SIGNAL INDICATOR LIGHT “” 2When the turn signals are beingoperated either to the right or tothe left the indicator will flash atthe same time.

If a turn signal light is not operat-ing properly due to bulb filamentor circuit failure, the indicator lightflickers more frequently than nor-mal to notify the rider of the exist-ence of a failure.

FI

E F

A B

GEAR

3-8

OIL PRESSURE INDICATOR LIGHT “” 3This indicator light comes onwhen the engine oil pressure isbelow the normal operatingrange.

NEUTRAL INDICATOR LIGHT “N” 4The green light will come on whenthe transmission is in neutral. Thelight will go out when you shift intoany gear other than neutral.

COOLANT TEMPERATURE INDICATOR LIGHT “” 5This indicator light comes onwhen the coolant temperatureindicates more than 120°C(248°F).

CAUTIONRiding the motorcycle with theoil pressure indicator light litcan damage the engine andtransmission.

Whenever the oil pressure indi-cator lights up, indicating lowoil pressure, stop the engineimmediately. Check the oil leveland determine if the properamount of oil is in the engine. Ifthe light still does not go out,have your authorized SUZUKIdealer or a qualified mechanictroubleshoot your motorcycle.

FI

E F

A B

GEAR

CAUTIONRunning the engine with highengine coolant temperaturecan cause serious engine dam-age. If the engine coolant tem-perature indicates greater than120°C (248°F) and the indicatorlight comes on, stop the engineto let it cool.

Do not run the engine until thecoolant temperature indicates120°C (248°F) or below.

3-9

FUEL INJECTION SYSTEM INDICATOR “FI” 6

If the fuel injection system fails,the red indicator light 6 comes onand the display indicates “FI” atthe clock display in the followingtwo modes;

A. The display 7 indicates “FI”intermittently, and the red indi-cator light 6 comes on andremains lit.

B. The display 7 indicates “FI”continuously and the red indi-cator light 6 blinks whilecranking the engine.

The engine may continue to run inmode A, but the engine will notrun in mode B.

NOTE: • If the display indicates “FI”

intermittently and the red indi-cator light comes on andremains lit, keep the enginerunning and bring your motor-cycle to an authorized Suzukidealer. If the engine stalls, tryrestarting the engine afterturning the ignition switch offand on.

• If the display indicates “FI”continuously and the red indi-cator light blinks, the enginewill not start.

CAUTIONRiding the motorcycle with thedisplay indicating a problemwith the fuel injection systemand with the indicator light litcan damage the engine.

Whenever the red indicatorlight is lit and the display indi-cates “FI”, have your autho-rized Suzuki dealer or aqualified mechanic inspect thefuel injection system as soonas possible.

3-10

When the display indicates“CHEC”, check following items;• Make sure that the engine stop

switch is in the “” position.• Make sure that the transmis-

sion is in neutral or the sidestand is fully up.

If the display still indicates“CHEC” after checking the aboveitems, inspect the ignition fuseand the connection of the leadwire couplers.

COMBINATION SYSTEM DISPLAY 7The display has five functions,clock, odometer, two trip metersand gear position. When the igni-tion switch is turned to the “ON”position, the display indicates thetest pattern shown below for twoseconds.

FI

E F

A B

GEAR

A B

GEAR

3-11

To change the display, push thebutton 8. The display changes inthe order below.

Clock The clock has a 12-hour display.Follow the procedure below toadjust the clock.

1. Push the buttons, 8 and 9,simultaneously for 2 secondsuntil the hour display blinks.

2. Adjust the hour display bypushing the button 9.

NOTE: When the button 9 is heldin the display advances continu-ously.

3. Push the button 8 to highlightthe minute display.

4. Adjust the minute display bypushing the button 9.

5. Push the button 8 to return tothe clock mode.

OdometerThe odometer registers the totaldistance that the motorcycle hasbeen ridden. The odometerranges from 0 to 999999 miles.

WARNINGOperating the display whileriding can be hazardous.Removing a hand from the han-dlebars can reduce your abilityto control the motorcycle.

Always keep both hands on thehandlebars during operation.

GEAR

A

GEAR

B

GEAR

Odometer

Trip meter A

Trip meter B

3-12

Trip MetersThe two trip meters are resettableodometers. They can register twokinds of distances at the sametime. For instance, trip meter Acan register the trip distance andtrip meter B can register the dis-tance between fuel stops.

To reset a trip meter to zero, pushthe button 9 for 2 seconds whilethe display indicates the trip meterA, or B, you want to reset.

NOTE: When the trip meterexceeds 9999.9, the trip meter willreturn to 0.0 and start countingagain.

Gear Position IndicatorThe gear position indicator indi-cates gear position. This indica-tor displays “0” when thetransmission is in neutral.

NOTE: When the display indi-cates “CHEC”, the gear positionindicator does not indicate a num-ber but indicates “–”.

FUEL METER “” 0The fuel meter indicates theamount of fuel remaining in thefuel tank. The fuel meter displaysall 5 segments when the fuel tankis full. The segment comes onwhen the fuel level drops below3.5 L (3.7 US qt). The segmentflicker when the fuel drops below1.5 L (1.6 US qt).

HIGH BEAM INDICATOR LIGHT “” AThis blue indicator light will comeon when the headlight high beamis turned on.

FI

E F

A B

GEAR

Fuel tank

Fuel gauge

Approximately1.5 L

Full

Flicker

Approximately3.5 L

3-13

LEFT HANDLEBAR

Clutch Lever 1The clutch lever is used for disen-gaging the drive to the rear wheelwhen starting the engine or shift-ing transmission gears. Squeez-ing the lever disengages theclutch.

Headlight Flasher Switch 2Press the switch to flash theheadlight.

Dimmer Switch 3“” positionThe headlight low beam and tail-light turn on.

“” positionThe headlight high beam and tail-light turn on. The high beam indi-cator light also turns on.

CAUTIONHolding the dimmer switchbetween “” and “” positionwill light both “” and “”headlight beam. This operationcan damage the motorcycle.

Use the dimmer switch only at“” or “” position.

CAUTIONSticking some tape or placingobjects in front of the headlightcan damage the headlight.

Do not stick any tapes to theheadlight. Do not place objectsin front of the headlight.

3-14

Turn Signal Switch “” 4Moving the switch to the “”position will flash the left turn sig-nals. Moving the switch to the “”position will flash the right turnsignals. The indicator light willalso flash intermittently. To cancelturn signal operation, push theswitch in.

Horn Button “” 5Press the button to sound thehorn.

Hazard Warning Switch “” 6 All four turn signal lights and indi-cators will flash simultaneouslywhen the switch is turned on withthe ignition switch in the “ON” or“P” position. Use the hazardwarning lights to warn other trafficduring emergency parking orwhen your vehicle could other-wise become a traffic hazard.

WARNINGFailure to use the turn signals,and failure to turn off the turnsignals can be hazardous.Other drivers may misjudgeyour course and this mayresult in an accident.

Always use the turn signalswhen you intend to changelanes or make a turn. Be sureto turn off the turn signals aftercompleting the turn or lanechange.

3-15

RIGHT HANDLEBAR

Engine Stop Switch 1“” positionThe ignition circuit is off. Theengine cannot start or run.

“” positionThe ignition circuit is on and theengine can run.

Front Brake Lever 2Apply the front brake by squeez-ing the front brake lever towardthe grip. The brake light will comeon when the lever is squeezed.

Front Brake Lever Adjustment

The distance between the throttlegrip and the front brake lever isadjustable to 5 positions. Tochange the position, push thebrake lever forward and turn theadjuster to the desired position.Be sure the adjuster stops in theproper position; a projection of thebrake lever holder should fit intothe depression of the adjuster.This motorcycle is delivered fromthe factory with its adjuster set onposition 3.

WARNINGAdjusting the front brake leverposition while riding can behazardous. Removing a handfrom the handlebars canreduce your ability to controlthe motorcycle.

Always keep both hands on thehandlebars while riding.

3-16

Electric Starter Button “” 3Use this button to operate thestarter motor. With the ignitionswitch in the “ON” position, theengine stop switch in the “”position, and the transmission inneutral, pull in the clutch lever andpush the electric starter button tostart the engine.

NOTE: This motorcycle has astarter interlock system for theignition and starter circuit. Theengine can only be started if:• The transmission is in neutral

and the clutch is disengaged,or

• The transmission is in gear,the side stand is fully up andthe clutch is disengaged.

NOTE: The headlight will go offwhen the electric starter button ispushed.

Throttle Grip 4Engine speed is controlled by theposition of the throttle grip. Turn ittoward you to increase enginespeed. Turn it away from you todecrease engine speed.

CAUTIONTo prevent electrical systemdamage, do not operate thestarter motor longer than fiveseconds at a time.

If the engine does not startafter several attempts, checkthe fuel supply and ignitionsystem. Refer to the TROUBLE-SHOOTING section in this man-ual.

3-17

FUEL TANK CAP

To open the fuel tank cap, insertthe ignition key into the lock andturn it clockwise. With the keyinserted, lift the cap up with key.To close the fuel tank cap, pushthe cap down firmly with the key inthe cap lock.

NOTE: Place the motorcycle onthe side stand to fill up the fueltank to specified 15.5 L (4.1 USgal).

1 Fuel level2 Filler neck

WARNINGOverfilling the fuel tank cancause the fuel to overflowwhen it expands due to heatfrom the engine or the sun.Spilled fuel can catch on fire.

Never fill the fuel above thebottom of the filler neck.

WARNINGFuel and fuel vapor are highlyflammable and toxic. You canbe burned or poisoned whenrefueling.

• Stop the engine and keepflames, sparks and heatsources away.

• Refuel only outdoors or in awell ventilated area.

• Do not smoke.• Wipe up spills immediately.• Avoid breathing fuel vapor.• Keep children and pets away.

3-18

GEARSHIFT LEVER

This motorcycle has 5-speedtransmission which operates asshown. To shift properly, pull theclutch lever and close the throttleat the same time you operate thegearshift lever. Lift the front end ofthe gear shift lever or depress therear end of the gearshift lever toupshift. Depress the front end ofthe gearshift lever to downshift.Neutral is located between 1stand 2nd gear. When neutral isdesired, depress or lift the leverhalfway between 1st and 2ndgear.

NOTE: When the transmission isin neutral, the green indicator lighton the instrument panel will be lit.However, even though the light islit, cautiously and slowly releasethe clutch lever to make sure thatthe transmission is positively inneutral.

REAR BRAKE PEDAL

Pressing the rear brake pedal willapply the rear brake. The brakelight will come on when the rearbrake is operated.

3-19

HELMET HOLDER

The helmet holder is located onthe left side below the rear seat.Insert the ignition key into the lockand turn it clockwise to open thelatch. Hook your helmet fastenerring to the latch and turn the keyback to lock the holder.

SIDE STAND

The motorcycle has a side stand.To place the motorcycle on theside stand, place your right footon the end of the side stand andpush down firmly until the standpivots fully through its arc andcomes to rest against it stop.

An interlock system is provided tocut off the ignition circuit when theside stand is down and the trans-mission is in any gear other thanneutral.

The side stand/ignition interlocksystem works as follows:• If the side stand is down and

the transmission is in gear, theengine cannot be started.

• If the engine is running and thetransmission is shifted intogear with the side stand down,the engine will stop running.

• If the engine is running and theside stand is put down with thetransmission in gear, theengine will stop running.

WARNINGRiding with a helmet fastenedto the helmet holder can inter-fere with rider control.

Never carry a helmet fastenedto the helmet holder. Fix thehelmet securely atop the seat ifyou must carry it.

3-20

SUSPENSION ADJUSTMENT

REAR SUSPENSION Spring Pre-load AdjustmentThe rear suspension spring pre-load is adjustable to compensatefor rider, load, riding style androad conditions. The adjustmentcan be performed in seven posi-tions. To change the spring pre-load setting, follow the procedurebelow.

1. Place the motorcycle on theside stand.

2. Insert the ignition key into thelock and turn it counterclock-wise. Unhook the hooks andremove the right frame cover.

WARNINGRiding with the side standincompletely retracted canresult in an accident when youturn left.• Check operation of the side

stand/ignition interlock sys-tem before riding.

• Always retract the side standcompletely before startingoff.

CAUTIONPark the motorcycle on firm,level ground to help prevent itfrom falling over.

If you must park on an incline,aim the front of the motorcycleuphill and put the transmissioninto 1st gear to reduce the pos-sibility of rolling off the sidestand.

3-21

3. Pull the hook to open the boxlid.

4. Unhook the hooks and removethe cover.

5. Loosen the bolts and removethe tool box.

6. Twist the spring tension ring tothe desired position with anadjuster. Position 1 providesthe softest spring tension andposition 7 provides the stiffest.This motorcycles is deliveredfrom the factory with itsadjuster set on position 4.

NOTE: Use a hook type springadjuster or Suzuki spring adjuster,Part number 09822-00003 toadjust the rear suspension spring.The Suzuki spring adjuster isavailable from your Suzuki dealer.

NOTE: If it is hard to adjust thespring pre-road, remove the boltsand move the battery box.

4-1

4


BREAK-IN ............................................................................................................ 4-2INSPECTION BEFORE RIDING .......................................................................... 4-3

4-2


BREAK-INThe first 800 km (500 miles) is themost important in the life of yourmotorcycle. Proper operation dur-ing this break-in period will helpassure maximum life and perfor-mance from your new motorcycle.The following guidelines explainproper break-in procedures.

Maximum Throttle Opening RecommendationThe table below shows the maxi-mum throttle opening recommen-dation during the break-in period.

Vary the Engine SpeedVary the engine speed during thebreak-in period. This allows theparts to “load” (aiding the matingprocess) and then “unload”(allowing the parts to cool).Although it is essential to placesome stress on the engine com-ponents during break-in, you mustbe careful not to load the enginetoo much.

Breaking in the New TiresNew tires need proper break-in toassure maximum performance,just as the engine does. Wear inthe tread surface by graduallyincreasing your cornering leanangles over the first 160 km (100miles) before attempting maxi-mum performance. Avoid hardacceleration, hard cornering, andhard braking for the first 160 km(100 miles).

Allow the Engine Oil to Circulate before RidingAllow enough idling time afterwarm or cold engine start-upbefore revving the engine or plac-ing the transmission in gear. Thisallows time for the lubricating oilto reach all critical engine compo-nents.

Up to 800 km(500 miles)

Less than 1/2 throttle

Up to 1600 km(1000 miles)

Less than 3/4 throttle

WARNINGFailure to perform break-in ofthe tires could cause tire slipand loss of control.

Use extra care when riding onnew tires. Perform properbreak-in of the tires asdescribed in this section andavoid hard acceleration, hardcornering, and hard braking forthe first 160 km (100 miles).

4-3

Observe Your Initial and Most Critical ServiceThe initial service (1000 km main-tenance) is the most importantservice your motorcycle willreceive. During break-in opera-tion, all of the engine componentswill have mated together andseated. Maintenance required aspart of the initial service includescorrection of all adjustments,tightening of all fasteners andreplacement of dirty oil. Timelyperformance of this service willhelp make sure you get the bestservice life and performance fromthe engine.

INSPECTION BEFORE RIDING

WARNINGFailure to inspect and maintainyour motorcycle properlyincreases the chance of anaccident or equipment dam-age.

Always perform a pre-rideinspection before each ride.Refer to the table or page 4-4for check items. For furtherdetails, refer to the INSPEC-TION AND MAINTENANCE sec-tion.

WARNINGUsing worn, improperlyinflated, or incorrect tires willreduce stability and can causean accident.

Follow all instructions in theTIRES section in this owner’smanual.

4-4

Check the condition of the motor-cycle to help make sure that youdo not have mechanical problemsor get stranded somewhere whenyou ride. Before riding the motor-cycle, be sure to check the follow-ing items. Be sure yourmotorcycle is in good condition forthe personal safety of the rider,passenger and protection of themotorcycle.

WARNINGChecking maintenance itemswhen the engine is running canbe hazardous. You could beseverely injured if your handsor clothing gets caught in mov-ing parts.

Shut the engine off when per-forming maintenance checks,except when checking theengine stop switch and throt-tle.

WHAT TO CHECK CHECK FOR:

Steering • Smoothness• No restriction of movement• No play or looseness

Brakes • Proper pedal and lever operation

• Correct fluid level• No fluid leakage• No “sponginess”• Proper pedal and lever play• Brake pad wear• Brake shoe wear

Tires • Proper pressure• Enough tread depth• No cracks, rips, or other

damage

Fuel tank Tank cap locked securely

Lighting Operation of all lights and indicators

Engine stop switch

Proper operation

Horn Correct function

Engine oil Correct level

Cooling system

• Proper coolant level• No leaks or damage

Gear oil Correct level

Throttle • Proper play• Smooth response• Quick return to idle position

Gearshift lever

• No damage• Smooth operation

Clutch • Smooth and progressive action

• Proper lever play

Side stand/ignition inter-lock system

Proper operation

General condition

• Bolts and nuts tightness• No rattle from any parts of

machine with the engine running

• No visible evidence of damage

5

5-1

RIDING TIPS

STARTING THE ENGINE .................................................................................... 5-2STARTING OFF AND SHIFTING ........................................................................ 5-3USING THE TRANSMISSION ............................................................................. 5-4RIDING ON HILLS ............................................................................................... 5-5STOPPING AND PARKING ................................................................................ 5-5CARRYING A PASSENGER ............................................................................... 5-7

5-2

RIDING TIPS

STARTING THE ENGINEBefore attempting to start theengine, make sure:• The transmission is in neutral.• The engine stop switch is in

the “” position.

NOTE: This motorcycle has inter-lock switches for the ignition cir-cuit and the starter circuit. Theengine can only be started if:• The transmission is in neutral

and the clutch is disengaged,or

• The transmission is in gear,the side stand is fully up, andthe clutch is disengaged.

When the Engine is Cold:1. Close the throttle completely.2. Squeeze the clutch lever and

push the electric starter but-ton.

3. After the engine starts, let theengine run until engine suffi-ciently warms up.

When the Engine is Warm:Close the throttle completely andpush the electric starter button.

When a Warm Engine is Hard to Start:Open the throttle 1/8 to 1/4 turnand push the electric starter but-ton.

WARNINGRunning the engine indoors orin a garage can be hazardous.Exhaust gas contains carbonmonoxide, a gas that is color-less and odorless and cancause death or severe injury.

Only run the engine outdoorswhere there is fresh air.

CAUTIONRunning the engine too longwithout riding may cause theengine to overheat. Overheat-ing can result in damage tointernal engine componentsand discoloration of exhaustpipes.

Shut the engine off if you can-not begin your ride promptly.

5-3

STARTING OFF AND SHIFTING

Make sure that the side stand is inthe fully up position. Pull theclutch lever in and pause momen-tarily. Engage first gear bydepressing the gearshift leverdownward. Turn the throttle grip alittle toward you and at the sametime release the clutch lever gen-tly and smoothly. As the clutchengages, the motorcycle will startmoving forward. To shift to thenext higher gear, accelerate gen-tly, then close the throttle and pullthe clutch lever in simultaneously.Lift the gearshift lever upward toselect the next gear and releasethe clutch lever as you open thethrottle again. Select higher gearsin this manner until top gear isreached.

NOTE: This motorcycle has a sidestand/ignition interlock switch. Ifyou shift the transmission intogear when the side stand is down,the engine will stop running.

WARNINGRiding this motorcycle atexcessive speed increasesyour chances of losing controlof the motorcycle. This mayresult in an accident.

Always ride within the limits ofyour skills, your motorcycle,and the riding conditions.

WARNINGRemoving your hands from thehandlebars or feet from thefootrests during operation canbe hazardous. If you removeeven one hand or foot from themotorcycle, you can reduceyour ability to control themotorcycle.

Always keep both hands on thehandlebars and both feet onthe footrests of your motorcy-cle during operation.

WARNINGSudden side winds, which canoccur when being passed bylarger vehicles, at tunnel exitsor in hilly areas, can upset yourcontrol.

Reduce your speed and bealert to side winds.

5-4

USING THE TRANSMISSIONThe transmission is provided tokeep the engine operatingsmoothly in its normal operatingspeed range. The gear ratioshave been carefully chosen tomeet the characteristics of theengine. The rider should alwaysselect the most suitable gear forthe prevailing conditions. Neverslip the clutch to control roadspeed, but rather downshift toallow the engine to run within itsnormal operational range. Thetable below shows the approxi-mate speed range for each gear.

Shifting up schedule

Shifting down schedule

Disengage the clutch when themotorcycle speed drops below 20km/h (12 miles/h).

Gear position miles/h km/h

1st → 2nd 12 20

2nd → 3rd 19 30

3rd → 4th 25 40

4th → Top 31 50

Gear position miles/h km/h

Top → 4th 19 30

WARNINGDownshifting when enginespeed is too high can:• cause the rear wheel to skid

and lose traction due toincreased engine braking,resulting in an accident; or

• force the engine to overrev inthe lower gear, resulting inengine damage.

Reduce speed before down-shifting.

WARNINGDownshifting while the motor-cycle is leaned over in a cornermay cause rear wheel skid andloss of control.

Reduce your speed and down-shift before entering a corner.

5-5

RIDING ON HILLS• When climbing steep hills, the

motorcycle may begin to slowdown and show lack of power.At this point you should shift toa lower gear so that the enginewill again be operating in itsnormal power range. Shift rap-idly to prevent the motorcyclefrom losing momentum.

• When riding down a steep hill,the engine may be used forbraking by shifting to a lowergear.

• Be careful, however, not toallow the engine to overrev.

STOPPING AND PARKING1. Turn the throttle grip away from

you to close the throttle com-pletely.

2. Apply the front and rear brakesevenly and at the same time.

3. Downshift through the gearsas motorcycle speeddecreases.

4. Select neutral with the clutchlever squeezed toward the grip(disengaged position) just be-fore the motorcycle stops. Theneutral position can be con-firmed by observing the neu-tral indicator light.

WARNINGInexperienced riders tend tounderutilize the front brake.This can cause excessive stop-ping distance and lead to a col-lision. Using only the front orrear brake can cause skiddingand loss of control.

Apply both brakes evenly andat the same time.

WARNINGHard braking while turning maycause wheel skid and loss ofcontrol.

Brake before you begin to turn.

5-6

5. Park the motorcycle on a firm,flat surface where it will not fallover.

6. Turn the ignition switch to the“OFF” position.

7. Turn the handlebars all theway to the left and lock thesteering for security.

8. Remove the keys.

NOTE: If an optional anti-theftlock such as U-shape lock, brakedisk lock and chain is used toavoid theft, be sure to removeanti-theft lock before moving themotorcycle.

WARNINGHard braking on wet, loose,rough, or other slippery sur-faces can cause wheel skidand loss of control.

Brake lightly and with care onslippery or irregular surfaces.

WARNINGFollowing another vehicle tooclosely can lead to collision.As vehicle speeds increase,stopping distance increasesprogressively.

Be sure you have a safe stop-ping distance between you andthe vehicle in front of you.

WARNINGA hot muffler can burn you.The muffler will be hot enoughto burn you for some time afterstopping the engine.

Park the motorcycle wherepedestrians or children are notlikely to touch the muffler.

5-7

CARRYING A PASSENGERBefore you invite someone to be apassenger on your motorcycle,you need to be thoroughly familiarwith motorcycle operation. Adjusttire pressures and suspensionaccording to the Tire Pressureand Loading section and the Sus-pension section of this manual.

The passenger should alwayshold onto your waist or hips, oronto the seat strap or grab bar, asequipped. Ask your passengernot to make any sudden move-ments. When you lean goingaround a corner, the passengershould lean with you. The passen-ger should always keep his or herfeet on the footrests, even whenyou are stopped at a light.

To help prevent burn injuries,warn your passenger not to con-tact the muffler when mounting ordismounting your motorcycle.

6-1

6


ACCESSORY USE .............................................................................................. 6-2ACCESSORY INSTALLATION GUIDELINE ....................................................... 6-2LOADING LIMIT .................................................................................................. 6-3LOADING GUIDELINES ...................................................................................... 6-4MODIFICATION ................................................................................................... 6-4

6-2


ACCESSORY USEThe addition of unsuitable acces-sories can lead to unsafe operat-ing conditions. It is not possiblefor Suzuki to test each accessoryon the market or combinations ofall the available accessories; how-ever, your dealer can assist you inselecting quality accessories andinstalling them correctly. Useextreme caution when selectingand installing the accessories onyour motorcycle and consult yourSuzuki dealer if you have anyquestions.

ACCESSORY INSTALLATION GUIDELINE• Install aerodynamic affecting

accessories, such as a fairing,windshield, backrests, saddle-bags, and travel trunks, as lowas possible, as close themotorcycle and as near to thecenter of gravity as is feasible.Check that the mountingbrackets and other attach-ment hardware are rigidlymounted.

• Inspect for proper groundclearance and bank angle.Inspect that the accessorydoes not interfere with theoperation of the suspension,steering or other control oper-ations.

• Accessories fitted to the han-dlebars or the front fork areacan create serious stabilityproblems. The extra weight willcause the motorcycle to beless responsive to your steer-ing control. The weight mayalso cause oscillations in thefront end and lead to instabilityproblems. Accessories addedto the handlebars or front forkof the machine should be aslight as possible and kept to aminimum.

• Certain accessories displacethe rider from his or her normalriding position. This limits thefreedom of movement of therider and may limit control abil-ity.

WARNINGImproper accessory installa-tion can make your motorcycleunsafe and can lead to an acci-dent.

Use Suzuki genuine accesso-ries or equivalent, designedand tested for your motorcycle.Follow the guidelines in thissection.

6-3

• Additional electrical accesso-ries may overload the existingelectrical system. Severe over-loads may damage the wiringharness or create a hazardoussituation due to the loss ofelectrical power during theoperation of the motorcycle.

• Do not pull a trailer or sidecar.This motorcycle is notdesigned to pull a trailer orsidecar.

LOADING LIMIT

• Never exceed the GVWR(Gross Vehicle Weight Rating)of this motorcycle. The GVWRis the combined weight of themachine, accessories, pay-load, rider and passenger.When selecting your accesso-ries, keep in mind the weight ofthe riders as well as the weightof the accessories. The addi-tional weight of the accesso-ries may not only create anunsafe riding condition butmay also affect the steeringease.

GVWR: 490 kg (1080 lbs) at thetire pressure (cold) Front: 200 kPa

(2.00 kgf/cm2, 29 psi)

(VL800T/C)225 kPa (2.25 kgf/cm2, 33 psi)

Rear: 250 kPa (2.50 kgf/cm2, 36 psi)

WARNINGOverloading or improper load-ing can cause loss of motorcy-cle control and this may resultin an accident.

Follow loading limits and load-ing guidelines in this manual.

6-4

LOADING GUIDELINESThis motorcycle is primarilyintended to carry small itemswhen you are not riding with apassenger. Follow the guidelinesbelow to carry a passenger orcargo:• Balance the load between the

left and right side of the motor-cycle and fasten it securely.

• Place cargo weight as close tothe center of the motorcycle aspossible.

• Do not attach large or heavyitems to the handlebars, frontforks or rear fender.

• Check that both tires are prop-erly inflated to the specifiedtire pressure for your loadingconditions. Refer to page 7-31.

• Improperly loading your motor-cycle can reduce your ability tobalance and steer the motor-cycle. You should ride atreduced speeds, less than 130km/h (80 mph), when you arecarrying cargo or have addedaccessories.

• Adjust suspension settings asnecessary.

MODIFICATIONModification of the motorcycle, orremoval of original equipmentmay render the vehicle unsafe orillegal. Obey all applicable equip-ment regulations in your area.

7-1

7


NOTICE ................................................................................................................ 7-2MAINTENANCE SCHEDULE .............................................................................. 7-2TOOLS ................................................................................................................. 7-5GENERAL LUBRICATION .................................................................................. 7-5BATTERY ............................................................................................................ 7-6AIR CLEANER ..................................................................................................... 7-7SPARK PLUG .................................................................................................... 7-11ENGINE OIL ....................................................................................................... 7-15ENGINE IDLE SPEED INSPECTION ................................................................ 7-19THROTTLE CABLE ADJUSTMENT ................................................................. 7-20FUEL HOSE ....................................................................................................... 7-20CLUTCH ADJUSTMENT ................................................................................... 7-22ENGINE COOLANT ........................................................................................... 7-23FINAL GEAR OIL .............................................................................................. 7-24BRAKES ............................................................................................................ 7-25TIRES ................................................................................................................. 7-30SIDE STAND/IGNITION INTERLOCK SYSTEM ............................................... 7-34FRONT WHEEL REMOVAL .............................................................................. 7-35REAR WHEEL REMOVAL ................................................................................ 7-37LIGHT BULB REPLACEMENT ......................................................................... 7-39FUSES ............................................................................................................... 7-42

7-2


NOTICE

MAINTENANCE SCHEDULEIt is very important to inspect andmaintain your motorcycle regu-larly. Follow the guidelines in thechart. The intervals between peri-odic services in kilometers, milesand months are shown. At theend of each interval, be sure toperform the maintenance listed.

MAINTENANCE, REPLACE-MENT OR REPAIR OF THEEMISSION CONTROLDEVICES AND SYSTEMSMAY BE PERFORMED BYANY MOTORCYCLE REPAIRESTABLISHMENT OR INDI-VIDUAL USING ANY MOTOR-CYCLE PART WHICH HASBEEN CERTIFIED UNDERTHE PROVISIONS IN THECLEAN AIR ACT Sec. 207(a)(2).

WARNINGImproper maintenance or fail-ure to perform recommendedmaintenance increases thechance of an accident ormotorcycle damage.

Always follow the inspectionand maintenance recommen-dations and schedules in thisowner’s manual. Ask yourSUZUKI dealer or a qualifiedmechanic to do the mainte-nance items marked with anasterisk (*). You may performthe unmarked maintenanceitems by referring to theinstructions in this section, ifyou have mechanical experi-ence. If you are not sure how todo any of the jobs, have yourSUZUKI dealer or a qualifiedmechanic do them.

7-3

NOTE: The MAINTENANCECHART specifies the minimumrequirements for maintenance. Ifyou use your motorcycle undersevere conditions, perform main-tenance more often than shown inthe chart. If you have any ques-tions regarding maintenanceintervals, consult your SUZUKIdealer or a qualified mechanic.

WARNINGNever run the engine indoorsor in a garage. Exhaust gascontains carbon monoxide, agas that is colorless and odor-less and can cause death orsevere injury.

Only run the engine outdoorswhere there is fresh air.

CAUTIONUsing poor quality replacementparts can cause your motorcy-cle to wear more quickly andmay shorten its useful life.

Use only genuine SUZUKI re-placement parts or their equiv-alent.

7-4

MAINTENANCE CHARTInterval: This interval should be judged by odometer reading or numberof months, whichever comes first.

NOTE: I= Inspect and clean, adjust, replace or lubricate as necessary, R= Replace, T= Tighten

NOTE: (California model only) and (CA. only) means that the item orthe maintenance interval is to be applied only for the California model.

Element

Interval km 1000 6000 12000 18000 24000

mile 600 4000 7500 11000 14500

months 2 12 24 36 48

Air cleaner element – I I R I

* Exhaust pipe bolts and muffler bolts T – T – T

* Valve clearance I – I – I

Spark plug – I R I R

Fuel hose– I I I I

* Replace every 4 years

Engine oil R R R R R

Engine oil filter R – – R –

Throttle cable play I I I I I

* Throttle valve synchronization I(CA only) – I – I

* Evaporative emission control system(California model only)

– – I – I

Replace vapor hose every 4 years

PAIR (air supply) system – – I – I

Engine coolant Replace every 2 years

Radiator hose – I I I I

Clutch – I I I I

Final gear oil R – I – I

* Brakes I I I I I

Brake hose– I I I I


Brake fluid– I I I I


Tires – I I I I

* Steering I – I – I

* Front forks – – I – I

* Rear suspension – – I – I

* Chassis bolts and nuts T T T T T

7-5

TOOLS

A tool kit is provided with yourmotorcycle. The toolbox is locatedon the left side of the motorcycle.To open the toolbox, refer to theSUSPENSION ADJUSTMENTsection.

GENERAL LUBRICATIONProper lubrication is important forsafe, smooth operation and a longlife for your motorcycle. Be surethat all lubrication is performedduring periodic maintenance onthe motorcycle. Increase fre-quency when you use your motor-cycle in severe conditions.

... Motor oil... Grease

1Clutch lever holder2Gearshift link pivots3Side stand pivot and spring

hook4Brake lever holder5Throttle cable6Brake pedal pivot

CAUTIONLubricating switches can dam-age the switches.

Do not apply grease and oil tothe switches.

7-6

BATTERYThe battery is a sealed type bat-tery and requires no mainte-nance. The standard chargingrate is 1.2A × 5 to 10 hours andthe maximum rate is 5.0A × 1hour.

Battery Removal1. Place the motorcycle on the

side stand.

2. Remove the bolt 1.

3. Push down the front end of therear seat 2 and pull the seatbackward.

4. Remove the bolts 3 and frontseat 4.

WARNINGBattery posts, terminals, andrelated accessories containlead and lead compounds.

Wash hands after handling.

WARNINGHydrogen gas produced by bat-teries can explode if exposedto flames or sparks.

Keep flames and sparks awayfrom the battery. Never smokewhen working near the battery.

CAUTIONExceeding the maximumcharging rate for the batterycan shorten its life.

Never exceed the maximumcharging rate.

7-7

5. Remove the battery.

NOTE: Remove the negative ter-minal first and then remove thepositive terminal.

6. To reinstall the battery, reversethe procedure above.

AIR CLEANERThe air cleaner element must bekept clean to provide good enginepower and gas mileage. If you useyour motorcycle under normal lowstress conditions, you should ser-vice the air cleaner at the intervalsspecified. If you ride in dusty, wet,or muddy conditions, you willneed to inspect the air cleanerelement much more frequently.Use the following procedure toremove the element and inspectit.

CAUTIONReversing the battery leadwires can damage the chargingsystem and the battery.

The red lead must go to thepositive (+) terminal and theblack (or black with whitetracer) lead must go to the neg-ative (–) terminal.

WARNINGOperating the engine withoutthe air cleaner element in placecould allow a flame to spit backfrom the engine to the aircleaner, or could allow dirt toenter the engine. This couldcause a fire or severe enginedamage.

Never run the engine withoutthe air cleaner element prop-erly installed.

7-8

Air Cleaner Element Removal1. Place the motorcycle on the

side stand.

2. Loosen the clamp bolt 1.

3. Remove the bolts 2 andunhook the hook 3. Pull theair cleaner 4.

CAUTIONClean or replace the air cleanerelement frequently if the motor-cycle is used in dusty, wet ormuddy conditions. The aircleaner element will clog underthese conditions, and this maycause engine damage, poorperformance, and poor fueleconomy.

Clean the air cleaner case andelement immediately if watergets in the air cleaner case.

7-9

4. Disconnect the tube 5 andcoupler 6.

5. Remove the screws. Removethe air cleaner case 7.

6. Remove the screws. Removethe air cleaner element 8.

7. Carefully use an air hose toblow the dust from the aircleaner element.

NOTE: Always apply air pressureto the mesh side of the air cleanerelement only. If you apply air pres-sure to the fabric side, dirt will beforced into the pores of the ele-ment, restricting the air flowthrough the element.

CAUTIONA torn air cleaner element willallow dirt to enter the engineand can damage the engine.

Carefully examine the aircleaner element for tears dur-ing cleaning. Replace it with anew one if it is torn.

7-10

8. Reinstall the air cleaner ele-ment in reverse order ofremoval. Be sure that the aircleaner element is securely inposition and is properlysealed.

Air Cleaner Drain Plug

Remove the plug and drain waterand oil at the periodic mainte-nance interval. The air cleanerdrain plug is located beneath theair cleaner box.

CAUTIONFailure to position the aircleaner element properly canallow dirt to bypass the aircleaner element. This willcause engine damage.

Be sure to properly install theair cleaner element.

7-11

SPARK PLUGYour motorcycle comes equippedwith DENSO X22EPR-U9,X22ESR-U (California) or NGKDPR7EA-9, DR7EA (California)spark plugs. To determine if thestandard spark plug is right foryour usage, check the color of theplug’s porcelain center electrodeinsulator after motorcycle opera-tion. A light brown color indicatesthat the plug is correct. A white ordark insulator indicates that theengine may need adjustment, oranother plug type may be needed.Consult your authorized Suzukidealer or a qualified mechanic ifyour plug insulator is not a lightbrown color.

California model

NOTE: If the above-named plugsare not available, consult yourauthorized Suzuki dealer.

NOTE: This motorcycle usesresistor-type spark plug to avoidjamming electronic parts.Improper spark plug selectionmay cause electronic interfer-ence with your motorcycle’s igni-tion system, resulting inmotorcycle performance prob-lems. Use only the recommendedspark plugs.

CAUTIONAn improper spark plug mayhave an incorrect fit or heatrange for your engine. Thismay cause severe engine dam-age which will not be coveredunder warranty.

Use one of the spark plugslisted below or equivalent.Consult your authorizedSUZUKI dealer or a qualifiedmechanic if you are not surewhich spark plug is correct foryour type of usage.

NGK DENSO REMARKS

DPR7EA-9 X22EPR-U9 Standard

DPR8EA-9 X24EPR-U9

If the standard plug is apt to overheat, replace with this plug.

NGK DENSO REMARKS

DR7EA X22ESR-U Standard

DR8EA X24ESR-U

If the standard plug is apt to overheat, replace with this plug.

7-12

Spark Plug Removal1. Place the motorcycle on the

side stand.2. Remove the air cleaner by

referring to the AIR CLEANERsection.

3. Remove the bolt and aircleaner bracket 1.

FRONT

REAR

4. Remove the bolt and open thecover 2.

7-13

FRONT

FRONT (California model)

REAR

REAR (California model)

5. Pull off the spark plug caps.6. Remove the spark plugs with a

spark plug wrench.

7-14

SPARK PLUG CLEANING

To maintain a hot, strong spark,keep the plugs free from carbon.Adjust the gap to 0.8 – 0.9 mm(0.031 – 0.035 in), 0.6 – 0.7 mm(0.024 – 0.028 in) (California) forgood ignition. Use a thickness(feeler) gauge to check the gap.

Installation

Carefully turn the spark plug byhand into the threads until it is fin-ger tight. If the spark plug is new,tighten it with a wrench about 1/2turn past finger tight. If you arereusing the old spark plug, tightenit with a wrench about 1/8 turnpast finger tight.

0.6 – 0.7 mm(0.024 – 0.028 in)(California)

0.8 – 0.9 mm(0.031 – 0.035 in)

CAUTIONA crossthreaded or overtight-ened spark plug will damagethe aluminum threads of thecylinder head.

Follow the procedure below totighten the spark plug properly.

CAUTIONDirt can damage your engine ifit enters an open spark plughole.

Cover the spark plug holewhenever the spark plug isremoved.

7-15

ENGINE OILEngine life depends on oil amountand quality. Daily engine oil levelchecks and periodic changes aretwo of the most important mainte-nance items to be performed.

Engine Oil Level CheckFollow the procedure below toinspect the engine oil level.1. Start the engine and allow it to

idle for a few minutes.2. Stop the engine and wait

approximately three minutes.

3. Hold the motorcycle verticallyand inspect the engine oil levelthrough the engine oil levelinspection window. The engineoil level should be between the“L” (low) and “F” (full) lines.

CAUTIONThe engine oil level must bebetween the “L” (Low) line and“F” (Full) line, or engine dam-age may occur.

Check the oil level, through theinspection window, with themotorcycle held vertically onlevel ground before each use ofthe motorcycle.

7-16

ENGINE OIL AND FILTER CHANGEChange the engine oil and oil filterat the scheduled times. Theengine should always be warmwhen the engine oil is changed sothe engine oil will drain easily. Theprocedure is as follows:

1. Place the motorcycle on levelground on the side stand.

2. Remove the oil filler cap.

3. Remove the drain plug fromthe bottom of the engine anddrain the engine oil into a drainpan.

WARNINGEngine oil and exhaust pipescan be hot enough to burn you.

Wait until the engine oil drainplug and exhaust pipes arecool enough to touch with barehands before draining oil.

7-17

NOTE: Recycle or properly dis-pose of used oil.

Oil filter wrench(Part No. 09915-40620)

4. Turn the oil filter with a Suzuki“cap type” oil filter wrench or a“strap type” filter wrench of theproper size and remove the oilfilter.

5. Wipe off the mounting surfaceon the engine where the newfilter will be seated with aclean rag.

WARNINGNew and used oil can be haz-ardous. Children and pets maybe harmed by swallowing newor used oil. Repeated, pro-longed contact with usedengine oil may cause skin can-cer. Brief contact with used oilmay irritate skin.

• Keep new and used oil awayfrom children and pets.

• Wear a long-sleeve shirt andwaterproof gloves.

• Wash with soap if oil con-tacts your skin.

7-18

6. Smear a little engine oilaround the rubber gasket ofthe new oil filter.

7. Screw the new filter by handuntil the filter gasket contactsthe mounting surface (a smallresistance will be felt).

NOTE: To tighten the oil filterproperly, it is important to accu-rately identify the position atwhich the filter gasket first con-tacts the mounting surface.

8. Mark the top dead center posi-tion on the “cap type” filterwrench or on the oil filter. Usean oil filter wrench to tightenthe filter 2 turns or to specifiedtorque.

Oil filter tightening torque:20 N·m (2.0 kgf-m, 14.5 lbf-ft)

9. Reinstall the drain plug andgasket. Tighten the plugsecurely with a wrench.

CAUTIONUsing an oil filter with thewrong design or thread specifi-cations can cause oil leaks orengine damage.

Use a genuine SUZUKI oil filteror an equivalent filter designedfor your motorcycle.

Mark top dead center

Oil filter wrench

In the position at which the filtergasket first contactsthe mountingsurface.

Tighten the filter 2 turns or to specified torque.

7-19

10.Reinstall the drain plug andtighten it securely. Pour about3400 ml (3.6 US qt) of thespecified oil in the filler hole.(See FUEL, OIL AND COOL-ANT RECOMMENDATIONsection.)

NOTE: About 3000 ml (3.2 US qt)of oil will be required when chang-ing oil only.

11.Reinstall the oil filler cap. Startthe engine (while the motorcy-cle is outside on level ground)and allow it to idle for a fewminutes.

12.Turn the engine off and waitapproximately 3 minutes. Holdthe motorcycle vertically andrecheck the oil level on theengine oil inspection window.The oil level should be at the“F” (full) mark. If it is lower thanthe “L” mark, add oil until itreaches the “F” mark. Inspectthe areas around the drainplug and oil filter for leaks.

ENGINE IDLE SPEED INSPECTIONInspect the engine idle speed.The engine idle speed should be1000 – 1200 r/min when theengine is warm.

NOTE: If the engine idle speed isnot within the specified range, askyour Suzuki dealer or a qualifiedmechanic to inspect and repairthe motorcycle.

CAUTIONEngine damage may occur ifyou use oil that does not meetSUZUKI’s specifications.

Use the oil specified in theFUEL, OIL AND COOLANTRECOMMENDATION section.

7-20

THROTTLE CABLE ADJUSTMENT

2.0 – 4.0 mm(0.08 – 0.16 in)

To adjust the cable play:1. Loosen the lock nut 1.2. Turn the adjuster 2 so that the

throttle grip has 2.0 – 4.0 mm(0.08 – 0.16 in) play.

3. Tighten the lock nut 1.

FUEL HOSE

Fuel Tank Lift1. Place the motorcycle on the

side stand. Remove the seatby referring to the BATTERYsection.

2. Remove the bolt 1.

3. Unhook the hooks. Disconnectthe coupler 2 and remove theinstrument panel assembly.

WARNINGInadequate throttle cable playcan cause engine speed to risesuddenly when you turn thehandlebar. This can lead toloss of rider control.

Adjust the throttle cable playso that engine idle speed doesnot rise due to handlebarmovement.

7-21

4. Remove the bolt 3. Raise therear end of the fuel tank andslide it backward.

(For California)

5. Inspect the fuel hose for dam-age and fuel leakage. If anydefects are found, the fuelhose must be replaced.

NOTE: Lifting up the fuel tank toomuch can result in the fuel hosebecoming bent or twisted. Lift thefuel tank as little as possible anddisconnect the fuel hose. The fueltank in the above illustration islifted to show the fuel hose andcoupler clearly.

7-22

CLUTCH ADJUSTMENTClutch cable play should be 10 –15 mm (0.4 – 0.6 in) measured atthe clutch lever end. Adjust clutchcable play according to the follow-ing procedure:

Minor Adjustment

10 – 15 mm(0.4 – 0.6 in)

Loosen the lock nut 2. Turn theclutch cable adjuster 1 to providethe specified play.

Major Adjustment

1. Loosen the lock nuts 3. Turnthe lock nuts 3 counterclock-wise.

2. Remove the bolts. Remove thecovers 4 and 5.

7-23

3. Loosen the lock nut 6.4. Turn in the adjuster 7 until it

stops. Turn back the adjuster7 1/4 turns.

5. Hold the adjuster 7 with ascrewdriver and tighten thelock nut 6.

6. Turn the lock nuts 3 to obtainapproximately 10 – 15 mm(0.4 – 0.6 in) of free play at theclutch lever end as indicated.

7. If proper free play is not avail-able, loosen and turn the locknuts 3 until clutch lever hasproper free play.

8. Tighten the lock nuts 2 and3.

NOTE: Minor adjustment can beperformed at the clutch lever sideadjuster only.

ENGINE COOLANTCoolant level

The engine coolant solutionshould be between “F” (full) and“L” (low) level lines on the enginecoolant reservoir. If the level islower than “L” (low) level line,bring it up to “F” (full) level by add-ing 50:50 mixture of distilled waterand engine coolant.

To add mixed coolant:1. Place the motorcycle on the

side stand.

2. Remove the bolts 1 and cover2.

F

L

7-24

3. Remove the filler cap and addproperly mixed coolantthrough the filler hole.

NOTE: Adding only water willdilute the engine coolant andreduce its effectiveness. Add a50:50 mixture of engine coolantand water.

FINAL GEAR OILChange the gear oil as follows:1. Place the motorcycle on the

side stand.

2. Remove the oil filler cap 1.3. Drain the oil into a suitable

container by removing thedrain plug 2 from the bottomof the final gear case.

4. Reinstall the drain plug andtighten it securely after all theoil has been drained out. Holdthe motorcycle vertically andpour fresh oil through the fillerhole until the oil level reachesthe oil filler hole. Approxi-mately 200 – 220 ml (6.8 – 7.4US oz) of oil will be required.

5. Reinstall the oil filler cap.

WARNINGEngine coolant is harmful orfatal if swallowed or inhaled.

Do not drink antifreeze or cool-ant solution. If swallowed, donot induce vomiting. Immedi-ately contact a poison controlcenter or a physician. Avoidinhaling mist or hot vapors; ifinhaled, remove to fresh air. Ifcoolant gets in eyes, flush eyeswith water and seek medicalattention. Wash thoroughlyafter handling. Solution can bepoisonous to animals. Keepout of the reach of children andanimals.

7-25

NOTE: Recycle or properly dis-pose of used oil.

BRAKESThis motorcycle has front diskand rear drum brakes.

NOTE: Operating in mud, water,sand or other extreme conditionscan cause accelerated brakewear. If you operate your motorcy-cle under these conditions, thebrakes must be inspected moreoften than recommended in theMAINTENANCE SCHEDULE.

WARNINGOperating the motorcycle withtoo little final gear oil cancause the final drive unit tolock up and cause an accident.

Check for leaks and the correctlevel of final gear oil beforeeach use. Add oil if necessary.Tighten the drain plug securelyafter changing the gear oil.

WARNINGNew and used oil can be haz-ardous. Children and pets maybe harmed by swallowing newor used oil. Repeated, pro-longed contact with usedengine oil may cause skin can-cer. Brief contact with used oilmay irritate skin.

• Keep new and used oil awayfrom children and pets.

• Wear a long-sleeve shirt andwaterproof gloves.

• Wash with soap if oil con-tacts your skin.

WARNINGFailure to inspect and properlymaintain the brakes increasesyour chance of having an acci-dent.

Inspect the brake systembefore each use according tothe INSPECTION BEFORERIDING section. Follow theMAINTENANCE SCHEDULEsection to maintain your brakesystem.

7-26

FRONT BRAKEBrake Fluid

Check the brake fluid level in thefront brake fluid reservoir andinspect for brake pad wear andleaks.

WARNINGFailure to keep the brake fluidreservoir full with proper brakefluid can be hazardous. Thebrakes may not work correctlywithout the proper amount andtype of brake fluid. This couldlead to an accident.

Inspect the brake fluid levelbefore each use. Use onlyDOT4 brake fluid from a sealedcontainer. Never use or mix dif-ferent types of brake fluid. Ifthere is frequent loss of fluid,take your motorcycle to aSUZUKI dealer or a qualifiedmechanic for inspection.

WARNINGBrake fluid is harmful or fatal ifswallowed, and harmful if itcomes in contact with skin oreyes.

If swallowed, do not inducevomiting. Immediately contacta poison control center or aphysician. If brake fluid gets ineyes, flush eyes with water andseek medical attention. Washthoroughly after handling.Solution can be poisonous toanimals. Keep out of the reachof children and animals.

CAUTIONSpilled brake fluid can damagepainted surfaces and plasticparts.

Avoid spilling any fluid whenfilling the reservoir. Wipe upspills immediately.

7-27

Brake Pads

Inspect the front brake pads tosee if they are worn down to thegrooved wear limit lines 1. If apad is worn to the grooved wearlimit line, it must be replaced witha new one. After replacing thefront brake pads, the brake levermust be pumped several times.This will extend the pads to theirproper position.

NOTE: Do not squeeze the brakelever when the pads are not intheir positions. It is difficult topush the pistons back into posi-tion.

WARNINGRiding with worn brake padswill reduce braking perfor-mance and will increase yourchance of having an accident.

Inspect brake pad wear beforeeach use. Ask your SUZUKIdealer or a qualified mechanicto replace brake pads if anypad is worn to the limit.

WARNINGFailure to extend brake padsafter repair or replacement cancause poor braking perfor-mance and may result in anaccident.

Before riding, “pump” thebrake repeatedly until brakepads are pressed against thebrake disk and proper leverstroke and firm feel arerestored.

7-28

Rear Brake Pedal AdjustmentThe rear brake pedal position andthe free travel must be properlyadjusted. Adjust the brake pedalin the following manner:

95 – 105 mm(3.7 – 4.1 in)

1. Loosen the lock nut 1 for thepedal stopper bolt.

2. Adjust the brake pedal heightby turning the pedal stopperbolt 2 to locate the pedal 95 –105 mm (3.7 – 4.1 in) abovethe top face of the footrest.

3. Tighten the lock nut.

20 – 30 mm(0.8 – 1.2 in)

4. Adjust the free travel to 20 –30 mm (0.8 – 1.2 in) by turningin or out the brake adjustingnut 3.

7-29

Brake Lining Wear LimitThe motorcycle is equipped withthe brake lining wear limit indica-tor on rear brake. To check wearof the brake lining perform the fol-lowing:

Range Index mark

Fig.A The extension line of theindex mark is within therange.

Fig.B The extension line of theindex mark is out of therange.

1. Make sure the brake play isproperly adjusted.

2. While fully applying the brakecheck to see that the extensionline of the index mark is withinthe range on the brake panelas shown in Fig A.

3. If the extension line is out sidethis range as shown in the Fig.B, have the brake shoesreplaced by your authorizedSuzuki dealer or a qualifiedmechanic.

REAR BRAKE LIGHT SWITCH

The rear brake light switch islocated by the brake pedal pivot.To adjust the brake light switch,hold the switch body and turn theadjuster so that the brake light willcome on just before a pressurerise is felt when the brake pedal isdepressed.

WARNINGRiding with worn brake shoeswill reduce braking perfor-mance and will increase yourchance of having an accident.

Inspect brake shoe wear beforeeach use. Ask your SUZUKIdealer or a qualified mechanicto replace brake shoes if theshoes are worn to the limit.

7-30

TIRES

Tire Pressure and LoadingProper tire pressure and propertire loading are important factors.Overloading your tires can lead totire failure and loss of motorcyclecontrol.

Check tire pressure each daybefore you ride, and adjust tirepressure according to the tablebelow. Tire pressure should onlybe checked and adjusted beforeriding since riding will heat up thetires and lead to higher inflationpressure readings.

WARNINGFailure to follow these warn-ings may result in an accidentdue to tire failure. The tires onyour motorcycle form the cru-cial link between your motorcy-cle and the road.

Follow these instructions:• Check tire condition and

pressure, and adjust pres-sure before each ride.

• Avoid overloading yourmotorcycle.

• Replace a tire when worn tothe specified limit, or if youfind damage such as cuts orcracks.

• Always use the size and typeof tires specified in thisowner’s manual.

• Balance the wheel after tireinstallation.

• Read this section of theowner’s manual carefully.

WARNINGFailure to perform break-in ofthe tires could cause tire slipand loss of control.

Use extra care when riding onnew tires. Perform properbreak-in of the tires referring tothe BREAK-IN section andavoid hard acceleration, hardcornering, and hard braking forthe first 160 km (100 miles).

7-31

VL800

VL800T/C

Under-inflated tires make smoothcornering difficult, and can resultin rapid tire wear. Over-inflatedtires cause a smaller amount oftire to be in contact with the road,which can contribute to skiddingand loss of control.

NOTE: When you detect drops intire pressure, check the tire fornails or other punctures, or adamaged wheel rim. Tubelesstires sometimes lose pressuregradually when punctured.

Tire Condition and TypeTire condition and tire type affectmotorcycle performance. Cuts orcracks in the tires can lead to tirefailure and loss of motorcycle con-trol. Worn tires are susceptible topuncture failures and subsequentloss of motorcycle control. Tirewear also affects the tire profile,changing motorcycle handlingcharacteristics.

Check the condition of your tireseach day before you ride. Replacetires if tires show visual evidenceof damage, such as cracks orcuts, or if tread depth is less than1.6 mm (0.06 in) front, 2.0 mm(0.08 in) rear.

LOAD SOLO RIDING WITH LIGHT OR LITTLE

CARGO LOAD

DUAL RIDING OR SOLO RIDING

WITH HEAVY CARGO LOADTIRE

FRONT200 kPa

2.00 kgf/cm2 29 psi

200 kPa 2.00 kgf/cm2

29 psi

REAR250 kPa

2.50 kgf/cm2 36 psi


36 psi

LOAD SOLO RIDING WITH LIGHT OR LITTLE

CARGO LOAD

DUAL RIDING OR SOLO RIDING

WITH HEAVY CARGO LOADTIRE

FRONT225 kPa

2.25 kgf/cm2 33 psi


33 psi

REAR250 kPa

2.50 kgf/cm2 36 psi


36 psi

7-32

NOTE: The “Triangle mark” indi-cates the place where the wearbars are molded into the tire.When the wear bars contact theroad, it indicates that the tire wearlimit has been reached.

Whenever you replace a tire, usea tire of the size and type listedbelow. If you use a different sizeor type of tire, motorcycle han-dling may be adversely affected,possibly resulting in loss of motor-cycle control.

VL800

VL800T

VL800C

Always balance the wheel afterrepairing a puncture or replacingthe tire. Proper wheel balance isimportant to avoid variable wheel-to-road contact, and to avoiduneven tire wear.

FRONT REAR

SIZE 130/90-16M/C 67H

170/80-15M/C 77H

TYPE IRC GS-23F IRC GS-23R

FRONT REAR

SIZE 130/90-16M/C 67H

170/80-15M/C 77H

TYPE IRC GS-23F RW IRC GS-23R RW

FRONT REAR

SIZE 130/90-16M/C 67H

170/80-15M/C 77H

TYPE IRC GS-23F D IRC GS-23R D

7-33

VL800CWARNING

An improperly repaired,installed, or balanced tire cancause loss of control orshorten tire life.

• Ask your SUZUKI dealer or aqualified mechanic to per-form tire repair, replacement,and balancing becauseproper tools and experienceare required.

• Install tires according to therotation direction shown byarrows on the sidewall ofeach tire.

WARNINGFailure to follow these instructionsabout tubeless tires may result inan accident due to tire failure.Tubeless tires require different ser-vice procedures than tube tires.

• Tubeless tires require an air-tightseal between the tire bead andwheel rim. Special tire irons andrim protectors or a specializedtire mounting machine must beused for removing and installingtires to prevent tire or rim dam-age which could result in an airleak.

• Repair a puncture in tubelesstires by removing the tire andapplying an internal patch.

• Do not use an external repairplug to repair a puncture sincethe plug may work loose as aresult of the cornering forcesexperienced in a motorcycle tire.

• After repairing a tire, do notexceed 80 km/h (50 mph) for thefirst 24 hours, 130 km/h (80 mph)thereafter. This is to avoid exces-sive heat build-up which couldresult in a tire repair failure andtire deflation.

• Replace the tire if it is puncturedin the sidewall area, or if a punc-ture in the tread area is largerthan 6 mm (3/16 in). These punc-tures cannot be repaired ade-quately.

7-34

SIDE STAND/IGNITION INTERLOCK SYSTEM

Check the side stand/ignitioninterlock system for proper opera-tion as follows:1. Sit on the motorcycle in the

normal riding position, with theside stand up.

2. Shift into first gear, hold theclutch in, and start the engine.

3. While continuing to hold theclutch in, move the side standto the down position.

If the engine stops running whenthe side stand is moved to thedown position, then the sidestand/ignition interlock system isworking properly. If the enginecontinues to run with the sidestand down and the transmissionin gear, then the side stand/igni-tion interlock system is not work-ing properly. Have yourmotorcycle inspected by anauthorized Suzuki dealer or someother qualified service mechanic.

WARNINGIf the side stand/ignition inter-lock system is not workingproperly, it is possible to ridethe motorcycle with the sidestand in the down position.This may interfere with ridercontrol during a left turn.

Check the side stand/ignitioninterlock system for properoperation before riding. Checkthat the side stand is returnedto its full up position beforestarting off.

7-35

FRONT WHEEL REMOVAL1. Place the motorcycle on the

side stand.

2. Remove the cap. Loosen theaxle holder bolt 1. Loosen theaxle 2 temporarily.

NOTE: A special tool is necessaryto loosen the axle. The specialtool is available from a Suzukidealer.

3. Place an accessory servicestand or equivalent under theswing arm to help stabilize therear end. Carefully position ajack under the engine or chas-sis tubes and raise the jackuntil the front wheel is slightlyoff the ground.

4. Turn the axle counterclockwiseand draw it out.

5. Remove the speedometergear box 3.

CAUTIONImproper jacking may causedamage to the oil filter.

Do not apply the jack head tothe oil filter when jacking upthe motorcycle.

7-36

6. Slide the front wheel forward.

NOTE: Never squeeze the frontbrake lever with the wheelremoved. It is very difficult to forcethe pads back into the caliperassembly.

7. To reinstall the wheel assem-bly, reverse the sequencedescribed above.

8. After installing the wheel,apply the front brake severaltimes to restore the properlever stroke.

Front axle tightening torque:65 N·m (6.5 kgf-m, 47.0 lbf-ft)

Front axle holder bolt tighteningtorque:33 N·m (3.3 kgf-m, 24.0 lbf-ft)

NOTE: Be careful not to damagethe oil seal when installing thefront wheel.

WARNINGFailure to extend brake padsafter installing the wheel cancause poor braking perfor-mance and may result in anaccident.

Before riding, “pump” thebrake repeatedly until thebrake pads are pressed againstthe brake disks and properlever stroke and firm feel arerestored. Also check that thewheel rotates freely.

WARNINGFailure to torque bolts and nutsproperly could lead to an acci-dent.

Torque bolts and nuts to theproper specifications. If youare not sure of the proper pro-cedure, have your authorizedSUZUKI dealer or a qualifiedmechanic do this.

7-37

REAR WHEEL REMOVAL

1. Place the motorcycle on theside stand. Remove the seatby referring to the BATTERYsection.

2. Disconnect the coupler.Remove the bolts 1, 2.Remove the right and left rearframe with a rear fender 3.

3. Remove the brake adjuster nut4 and torque link nut 5.Remove the axle nut 6.

WARNINGRemoving the rear wheel with-out use of an accessory standcan result in your motorcyclefalling over and being dam-aged.

Do not attempt road sideremoval of the rear wheel. Onlyremove the rear wheel at aproperly equipped servicingfacility using an accessory ser-vice stand.

WARNINGA hot muffler can burn you. Themuffler will be hot enough toburn you for some time afterstopping the engine.

Wait until the muffler cools toavoid burns.

7-38

4. Place an accessory servicestand or equivalent under theswingarm or chassis tubes tostabilize the rear end.

5. Remove the cap 7.

6. Draw out the axle 8.

7. Remove the wheel from thesplined drive gear and set thewheel assembly on theground.

8. Pull the wheel assembly rear-ward.

9. To replace the wheel reversethe complete sequencedescribed above.

Rear axle tightening torque:65 N·m (6.5 kgf-m, 47.0 lbf-ft)

Rear torque link nut tightening torque: 25 N·m (2.5 kgf-m, 18.0 lbf-ft)

NOTE: Apply a drop of SUZUKITHREAD LOCK “1322” to the rearframe mounting bolt 1, 2.

Rear frame mounting bolt tightening torque: 50 N·m (5.0 kgf-m, 36.0 lbf-ft)

WARNINGFailure to torque bolts and nutsproperly and to properly applythread lock to specified boltsand nuts could lead to an acci-dent.

Torque bolts and nuts to theproper specifications. Properlyapply thread lock to specifiedbolts. If you are not sure of theproper procedure, have yourauthorized SUZUKI dealer or aqualified mechanic do this.

7-39

LIGHT BULB REPLACEMENTThe wattage rating of each bulb isshown in the following chart.When replacing a burned outbulb, always use the same watt-age rating.

Headlight

1. Remove right and left screws1. Remove the headlightassembly.

2. Disconnect socket 2 from theheadlight and rubber cap 3.

CAUTIONUsing a light bulb with thewrong wattage rating cancause electrical system dam-age or shorten bulb life.

Always use the specified lightbulb.

Headlight 12V 60/55W (H4)

Turn signal lightFront 12V 21/5W

Rear 12V 21W

License plate light 12V 5W

7-40

3. Unhook bulb holder spring 4,and pull out the bulb 5.

4. To replace the headlight bulb,reverse the above sequence.

Headlight Beam AdjustmentThe headlight beam can beadjusted both right and left or upand down if necessary.

To adjust the beam right and left:Turn the adjuster 1 clockwise orcounterclockwise.

To adjust the beam up and down:Turn the adjuster 2 clockwise orcounterclockwise.

CAUTIONOil from your skin may damagethe headlight bulb or shortenits life.

Grasp the new bulb with aclean cloth.

7-41

Turn Signal Light

1. Remove the screw 1.2. Turn the lens counterclockwise

and remove it.

3. Push in on the bulb 2, turn itto the left, and pull it out.

4. To fit the replacement bulb,push it in and turn it to the rightwhile pushing.

License Plate LightTo replace the license plate lightbulb, follow the procedure below:

1. Turn the license plate lenscounterclockwise and removeit.

2. Pull off the bulb from thesocket.

CAUTIONOvertightening the screwswhen reinstalling the lens maycause the lens to crack.

Tighten the screws only untilthey are snug.

7-42

FUSES

MAIN FUSE

The main fuse is located underthe front seat. To access the fuse,remove the seat by referring tothe BATTERY section.

One 30A spare fuse is located inthe fuse box.

FUSES

The fuses are located behind theleft crank case cover. To accessthe fuses, remove the left crankcase cover referring to theENGINE COOLANT section.

Two spare fuses (one 10A andone 20A) are provided inside thefuse box.

The fuses are designed to openwhen an overload exists in indi-vidual electrical system circuits. Ifany electrical system fails to oper-ate, then the fuses must bechecked.

30 30

7-43

FUSE LIST• 30A MAIN fuse protects all

electrical circuits.• 10A HEAD-HI fuse protects

the speedometer and head-light high beam.

• 10A HEAD-LO fuse protectsthe headlight low beam.

• 10A FUEL fuse protects theECU, fuel pump, injectors andspeedometer.

• 20A IGNITION fuse protectsthe *oxygen sensor, sole-noids, ECU, fuel pump relay,fan motor relay, starter relay,ignition coils, *canister purgesolenoid, headlight relay andside stand relay.

• 10A SIGNAL fuse protects thehorn, speedometer, pilot lamp,stop lamp, running lamp andresister.

• 10A POWER SOURCE fuseprotects the electrical acces-sories connected to output ter-minal.

* For California

CAUTIONInstalling a fuse of incorrectrating or using aluminum foil orwire instead of a fuse may seri-ously damage the electricalsystem.

Always replace a blown fusewith a fuse of the same typeand rating. If the new fuseblows in a short time, consultyour SUZUKI dealer or a quali-fied mechanic immediately.

8-1

8

TROUBLESHOOTING

FUEL SUPPLY CHECK ....................................................................................... 8-2IGNITION SYSTEM CHECK ................................................................................ 8-3

8-2

TROUBLESHOOTING

This troubleshooting guide is pro-vided to help you find the cause ofsome common complaints.

COMPLAINT: Engine is hard tostart or does not start at all.

FUEL SUPPLY CHECKIf the fuel injection indicator dis-plays “FI”, showing signs of trou-ble in the fuel injection system,take your machine to an autho-rized Suzuki dealer. Refer to the“INSTRUMENT PANEL” sectionfor an explanation of the fuelinjection system indicator. If theindicator does not display “FI”,make sure there is enough fuel inthe fuel tank. If the indicator doesnot display “FI” and there isenough fuel, the ignition systemshould be checked.

CAUTIONFailure to troubleshoot a prob-lem correctly can damage yourmotorcycle. Improper repairsor adjustments may damagethe motorcycle instead of fix-ing it. Such damage may not becovered under warranty.

If you are not sure about theproper action, consult yourauthorized Suzuki dealer or aqualified mechanic about theproblem.

8-3

IGNITION SYSTEM CHECK

1. Remove the spark plugs andreattach them to the sparkplug caps.

2. Put the engine stop switch inthe “” position and the igni-tion switch in the “ON” posi-tion. While holding the sparkplug with its base firmlyagainst the engine, push theelectric starter button. If theignition system is operatingproperly, a blue spark shouldjump across the spark pluggap. If there is no spark, takeyour machine to your autho-rized Suzuki dealer or a quali-fied mechanic.

COMPLAINT: Engine stalls.1. Make sure there is enough fuel

in the fuel tank.2. If the fuel injection indicator

displays “FI”, showing signs oftrouble in the fuel injection sys-tem, take your machine to anauthorized Suzuki dealer.Refer to the “INSTRUMENTPANEL” section for an explana-tion of the fuel injection systemindicator.

3. Check the ignition system forintermittent spark.

4. Check the idle speed. If neces-sary, adjust it using a tachom-eter. The correct idle speed is1000 – 1200 r/min.

WARNINGPerforming the spark testimproperly can cause a highvoltage electrical shock or anexplosion.

Avoid performing this check ifyou are not familiar with thisprocedure, or if you have aheart condition or wear a pace-maker. Keep the spark plugaway from the spark plug holeduring this test.

9-1

9


STORAGE PROCEDURE .................................................................................... 9-2PROCEDURE FOR RETURNING TO SERVICE ................................................. 9-3CORROSION PREVENTION ............................................................................... 9-4MOTORCYCLE CLEANING ................................................................................ 9-5INSPECTION AFTER CLEANING ....................................................................... 9-6

9-2


STORAGE PROCEDUREIf your motorcycle is to be leftunused for an extended period oftime, it needs special servicingrequiring appropriate materials,equipment and skill. For this rea-son, Suzuki recommends that youtrust this maintenance work toyour authorized Suzuki dealer. Ifyou wish to service the machinefor storage yourself, follow thegeneral guidelines below:

MOTORCYCLEClean the entire motorcycle.Place the motorcycle on the sidestand on a firm, flat surface whereit will not fall over.

FUEL1. Fill the fuel tank to the top with

fuel mixed with the amount ofgasoline stabilizer recom-mended by the stabilizer man-ufacturer.

2. Run the engine for a few min-utes until the stabilized gaso-line fills the fuel injectionsystem.

ENGINE1. Pour one tablespoon of motor

oil into each spark plug hole.Reinstall the spark plugs andcrank the engine a few times.

2. Drain the engine oil thoroughlyand refill the crankcase withfresh engine oil all the way upto the filler hole.

3. Cover the air cleaner intakeand the muffler outlet with oilyrags to prevent humidity fromentering.

BATTERY1. Remove the battery from the

motorcycle.2. Clean the outside of the bat-

tery with a mild soap andremove corrosion from the ter-minals and wiring harness.

3. Store the battery in a roomabove freezing.

9-3

TIRESInflate the tires to the normalspecifications.

EXTERNAL• Spray all vinyl and rubber

parts with rubber preservative.• Spray the unpainted surfaces

with rust preventative.• Coat the painted surfaces with

car wax.

MAINTENANCE DURING STORAGEOnce a month, recharge the bat-tery. The standard charging rate is1.2A × 5 to 10 hours.

PROCEDURE FOR RETURNING TO SERVICE1. Clean the entire motorcycle.2. Remove the oily rags from the

air cleaner intake and muffleroutlet.

3. Drain all the engine oil. Installa new oil filter and fill theengine with fresh oil as out-lined in this manual.

4. Reinstall the battery.5. Remove the spark plugs. Turn

the engine a few times. Rein-stall the spark plugs.

6. Make sure that the motorcycleis properly lubricated.

7. Perform the INSPECTIONBEFORE RIDING as listed inthis manual.

8. Start the motorcycle as out-lined in this manual.

9-4

CORROSION PREVENTIONIt is important to take good care ofyour motorcycle to protect it fromcorrosion and keep it looking newfor years to come.

Important Information About CorrosionCommon causes of corrosion• Accumulation of road salt, dirt,

moisture, or chemicals in hard-to-reach areas.

• Chipping, scratches, and anydamage to treated or paintedmetal surfaces resulting fromminor accidents or impactsfrom stones and gravel.

Road salt, sea air, industrial pollu-tion, and high humidity will all con-tribute to corrosion.

How to Help Prevent Corrosion• Wash your motorcycle fre-

quently, at least once a month.Keep your motorcycle as cleanand dry as possible.

• Remove foreign materialdeposits. Foreign material suchas road salt, chemicals, road oilor tar, tree sap, bird droppingsand industrial fall-out may dam-age your motorcycle’s finish.Remove these types of depos-its as quickly as possible. Ifthese deposits are difficult towash off, an additional cleanermay be required. Follow themanufacturer’s directions whenusing these special cleaners.

• Repair finish damage as soonas possible. Carefully exam-ine your motorcycle for dam-age to the painted surfaces.Should you find any chips orscratches in the paint, touchthem up immediately to pre-vent corrosion from starting. Ifthe chips or scratches havegone through to the baremetal, have a Suzuki dealermake the repair.

• Store your motorcycle in a dry,well-ventilated area. If youoften wash your motorcycle inthe garage or if you frequentlypark it inside when wet, yourgarage may be damp. Thehigh humidity may cause oraccelerate corrosion. A wetmotorcycle may corrode evenin a heated garage if the venti-lation is poor.

9-5

• Cover your motorcycle. Expo-sure to mid-day sun can causethe colors in paint, plasticparts, and instrument faces tofade. Covering your motorcy-cle with a high-quality, “breath-able” motorcycle cover canhelp protect the finish from theharmful UV rays in sunlight,and can reduce the amount ofdust and air pollution reachingthe surface. Your Suzukidealer can help you select theright cover for your motorcycle.

MOTORCYCLE CLEANINGWashing the MotorcycleWhen washing the motorcycle,follow the instructions below:1. Remove dirt and mud from the

motorcycle with running water.You may use a soft sponge orbrush. Do not use hard materi-als which can scratch thepaint.

2. Wash the entire motorcyclewith mild detergent or carwash soap using a sponge orsoft cloth. The sponge or clothshould be frequently soaked inthe soap solution.

NOTE: Avoid spraying or allowingwater to flow over the followingplaces:• Ignition switch• Spark plugs• Fuel tank cap• Throttle body• Fuel injection system• Brake master cylinder

CAUTIONRadiator fins can be damagedby spraying high pressurewater on them.

Do not spray high pressurewater on the radiator.

9-6

3. Once the dirt has been com-pletely removed, rinse off thedetergent with running water.

4. After rinsing, wipe off themotorcycle with a wet chamoisor cloth and allow it to dry inthe shade.

5. Check carefully for damage topainted surfaces. If there isany damage, obtain “touch-up”paint and “touch-up” the dam-age.

Waxing the MotorcycleAfter washing the motorcycle,waxing is recommended to furtherprotect and beautify the paint.Observe the precautions speci-fied by the wax manufacturer.

INSPECTION AFTER CLEANINGFor extended life of your motorcy-cle, lubricate according to GEN-ERAL LUBRICATION section.

Follow the procedures in theINSPECTION BEFORE RIDINGsection to check your motorcyclefor any problems that may havearisen during your last ride.

CAUTIONHigh pressure washers andparts cleaner can damage yourmotorcycle.

Do not use high pressurewashers to clean your motorcy-cle. Do not use parts cleaner tothrottle body and fuel injectionsensors.

CAUTIONCleaning with any alkaline orstrong acid cleaner gasoline,brake fluid, or any other sol-vent will damage the motorcy-cle parts.

Clean only with soft cloth andwarm water with mild deter-gent.

WARNINGWet brakes can cause poorbraking performance and maylead to an accident.

Avoid a possible accident byexpecting longer stopping dis-tances after washing yourmotorcycle. Apply brakes sev-eral times to let heat dry thebrake pads or shoes.

10

10-1


EMISSION CONTROL WARRANTY ................................................................. 10-2TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...................... 10-2SERIAL NUMBER LOCATION .......................................................................... 10-3REPORTING SAFETY DEFECTS ..................................................................... 10-4ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION .................. 10-5LOCATION OF LABELS ................................................................................... 10-6

10-2


EMISSION CONTROL WARRANTYSuzuki Motor Corporation war-rants to the ultimate purchaserand each subsequent purchaserthat this vehicle is designed, built,and equipped so as to conform atthe time of sale with all U.S. emis-sion standards applicable at thetime of manufacture, and that it isfree from defects in materials andworkmanship which would causeit not to meet these standardswithin its useful life. Useful life isdefined for each class of motorcy-cle as 5 years or the correspond-ing number of kilometers (miles)shown in the chart below, which-ever occurs first.

Failures, other than those result-ing from defects in material orworkmanship, which arise solelyas a result of owner abuse and/orlack of proper maintenance arenot covered by the warranty.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITEDFederal law prohibits the followingacts or the causing thereof; (1)the removal or rendering inopera-tive by any person other than forpurposes of maintenance, repair,or replacement, of any device orelement of design incorporatedinto any new vehicle for the pur-pose of noise control prior to itssale or delivery to the ultimatepurchaser or while it is in use, or(2) the use of the vehicle aftersuch device or element of designhas been removed or renderedinoperative by any person.

Vehicle Class

Engine Displacement

Useful Life Distance

Class I 50 to 169 cc 12000 km(7456 miles)

Class II 170 to 279 cc 18000 km(11185 miles)

Class III 280 cc and over

30000 km(18641 miles)

10-3

Among those acts presumed toconstitute tampering are the actslisted below:• removing or puncturing the

muffler, baffles, header pipes,screen type spark arrester (ifequipped) or any other compo-nent which conducts exhaustgases

• replacing the exhaust systemor muffler with a system ormuffler not marked with thesame model specific code asthe code listed on the Motorcy-cle Noise Emission ControlInformation label, and certifiedto appropriate EPA noise stan-dards

• removing or puncturing the aircleaner case, air cleanercover, baffles, or any othercomponent which conductsintake air.

Whenever replacing parts on yourmotorcycle, Suzuki recommendsthat you use genuine Suzukireplacement parts or their equiva-lent.

SERIAL NUMBER LOCATIONYou need to know the frame andengine serial numbers to get titledocuments for your motorcycle.You also need these numbers tohelp your authorized Suzukidealer when you order parts.

The frame number 1 is stampedon the steering head as shown inthe illustration. The engine serialnumber 2 is stamped on thecrankcase assembly.

Write down the serial numbershere for your future reference.

Frame No:

Engine No:

10-4

REPORTING SAFETY DEFECTSIf you believe that your vehiclehas a defect which could cause acrash or could cause injury ordeath, you should immediatelyinform the National Highway Traf-fic Safety Administration (NHTSA)in addition to notifying AmericanSuzuki Motor Corp.

If NHTSA receives similar com-plaints, it may open an investiga-tion, and if it finds that a safetydefect exists in a group of vehi-cles, it may order a recall andremedy campaign. However,NHTSA cannot become involvedin individual problems betweenyou, your authorized Suzukidealer, or American Suzuki MotorCorp.

To contact NHTSA, you mayeither call the Vehicle Safety HotLine toll-free 1-888-327-4236(TTY: 1-800-424-9153); go tohttp://www.safercar.gov; or writeto: Administrator, NHTSA, 400Seventh Street, SW., WashingtonDC 20590. You can also obtainother information about motorvehicle safety from http://www.NHTSA.gov.

To contact American Suzuki, own-ers in the continental UnitedStates can call toll-free 1-800-444-5077, or write to: AmericanSuzuki Motor Corporation Motor-cycle Customer Service P.O. Box1100, Brea, CA 92822-1100

For owners outside the continen-tal United States, please refer tothe distributor’s address listed onyour Warranty Information bro-chure.

10-5

ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATIONYour motorcycle is equipped withon-board computer systemswhich monitor and control severalaspects of motorcycle perfor-mance, including the following:• Emission-related components

and engine parameters suchas engine speed and throttleposition are monitored to pro-vide emission control and toprovide optimum fuel econ-omy. Your motorcycle also hasan on-board diagnostic systemwhich monitors and recordsinformation about emission-related malfunctions.

Some information may be storedby the on-board computer whenmalfunctions occur. This storedinformation can assist techni-cians in repairing the motorcycle.To read the stored information,special equipment is needed andaccess to the motorcycle or stor-age device is required. In addi-tion, once SUZUKI collects orreceives data, SUZUKI may usethe data for research conductedby SUZUKI, make the data avail-able for outside research if needis shown and confidentiality isassured, or make summary datawhich does not identify specificmotorcycles available for outsideresearch.

Others, such as law enforcementpersonnel, may have access tothe special equipment that canread the information if they haveaccess to the motorcycle or stor-age device.

10-6

LOCATION OF LABELSRead and follow all of the warn-ings labeled on your motorcycle.Make sure you understand all ofthe labels. Keep the labels onyour motorcycle. Do not removethem for any reason.

1

2

WARNINGFailure to follow these safetyprecautions may increase your riskof injury:

• Wear a helmet, eye protection, and bright protective clothing.

• Don’t ride after consuming alcohol or other drugs.

• Slow down on slippery surfaces,unfamiliar terrain, or when visibilityis reduced.

• Read owner’s manual carefully.

The owner’s manual contains important safety information and instructions which should be read carefully before operating the vehicle.If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance.

10-7

3 (VL800)

3 (VL800T)

3 (VL800C)

IRC

kgf/cm2

TYPE

kPa psi

TIRE SIZE

FRONT REAR

130/90-16M/C 67H 170/80-15M/C 77H

GS-23F GS-23R

SOLO RIDING DUAL RIDING

FRONTREAR

COLD TIREPRESSURE

200250

2.002.50

2936

WARNINGCheck tire condition,

wear, and cold tire

pressure before each ride.

Replace only with tires

of listed size and type.

Read Owner’s manual for

more information.

•

•

•

kgf/cm2kPa psi200250

2.002.50

2936

IRC

kgf/cm2

TYPE

kPa psi

TIRE SIZE

FRONT REAR

130/90-16M/C 67H 170/80-15M/C 77H

GS-23F RW GS-23R RW


FRONTREAR

COLD TIREPRESSURE

225250

2.252.50

3336

WARNINGCheck tire condition,

wear, and cold tire

pressure before each ride.

Replace only with tires

of listed size and type.

Read Owner’s manual for

more information.

•

•

•

kgf/cm2kPa psi225250

2.252.50

3336

IRC

kgf/cm2

TYPE

kPa psi

TIRE SIZE

FRONT REAR

130/90-16M/C 67H 170/80-15M/C 77H

GS-23F D GS-23R D


FRONTREAR

COLD TIREPRESSURE

225250

2.252.50

3336

WARNINGkgf/cm2kPa psi

225250

2.252.50

3336

Check tire condition,wear, and cold tirepressure before each ride.Replace only with TUBELESS tires of listed size and type.Read owner’s manual formore information.

SPECIFICATIONS

DIMENSIONS AND CURB MASSOverall length ..................................................2510 mm (98.8 in)Overall width.................................................... 970 mm (38.2 in)Overall height ..................................................1105 mm (43.5 in)Wheelbase ......................................................1655 mm (65.2 in)Ground clearance............................................ 140 mm (5.5 in)Seat height ...................................................... 700 mm (27.6 in)Curb mass ....................................................... 267 kg (589 lbs)

ENGINEType.................................................................Four-stroke, liquid-cooled, OHCNumber of cylinders ........................................2Bore.................................................................83.0 mm (3.268 in)Stroke ..............................................................74.4 mm (2.929 in)Displacement...................................................805 cm3 (49.1 cu. in)Compression ratio ...........................................9.4 : 1Fuel system.....................................................Fuel injectionAir cleaner .......................................................Non-woven fabric elementStarter system .................................................ElectricLubrication system ..........................................Wet sump

DRIVE TRAINClutch ..............................................................Wet multi-plate typeTransmission ...................................................5-speed constant meshGearshift pattern .............................................1-down, 4-upPrimary reduction ratio ....................................1.690 (71/42)Secondary reduction ratio ...............................1.000 (30/30)Gear ratios, Low ..............................................2.461 (32/13)

2nd...............................................1.631 (31/19)3rd ...............................................1.227 (27/22)4rd ...............................................1.000 (25/25)Top...............................................0.814 (22/27)

Final reduction ratio.........................................3.503 (17/15 × 34/11)Drive system....................................................Shaft drive

CHASSISFront suspension .............................................Telescopic, coil spring, oil dampedRear suspension .............................................Link type, coil spring, oil dampedFront suspension stroke ..................................140 mm (5.5 in)Rear wheel travel.............................................105 mm (4.1 in)Caster..............................................................33° 20’Trail ..................................................................141 mm (5.55 in)

138 mm (5.43 in) ... VL800CSteering angle .................................................38° (right & left)Turning radius..................................................3.0 m (9.8 ft)Front brake ......................................................Disk brakeRear brake.......................................................Drum brakeFront tire size...................................................130/90-16 M/C 67H, tube

130/90-16 M/C 67H, tubeless ... VL800CRear tire size ...................................................170/80-15 M/C 77H, tube

170/80-15 M/C 77H, tubeless ... VL800C

ELECTRICALIgnition type .....................................................Electronic ignition (Transistorized)Spark plug .......................................................NGK DPR7EA-9 or DENSO X22EPR-U9

NGK DR7EA or DENSO X22ESR-U ... For CaliforniaBattery.............................................................12V 36kC (10Ah)/10HRGenerator ........................................................Three-phase A.C. GeneratorMain fuse.........................................................30AFuse ................................................................20/10/10/10/10/10AHeadlight .........................................................12V 60/55W (H4)Brake light/Taillight...........................................LEDFront turn signal light .......................................12V 21/5WRear turn signal light .......................................12V 21WSpeedometer light ...........................................LEDNeutral indicator light.......................................LEDHigh beam indicator light.................................LEDTurn signal indicator light.................................LEDOil pressure indicator light...............................LEDCoolant temperature indicator light .................LEDFuel injection indicator light .............................LED

CAPACITIESFuel tank.......................................................... 15.5 L (4.1 US gal)Engine oil, without filter change.......................3000 ml (3.2 US qt)

With filter change ...........................3400 ml (3.6 US qt)Final gear oil....................................................200 – 220 ml (6.8 – 7.4 US oz)Engine coolant................................................. 1.5 L (1.6 US qt)

INDEX

AACCESSORIES AND LOADING. .............................. 1-5ACCESSORY INSTALLATION GUIDELINE............................ 6-2ACCESSORY USE ................ 6-2AIR CLEANER ....................... 7-7

BBATTERY............................... 7-6BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS................... 1-5BE STREET SMART.............. 1-6BRAKES............................... 7-25BREAK-IN .............................. 4-2

CCARRYING A PASSENGER...................1-6,5-7CLUTCH ADJUSTMENT ..................... 7-22CONCLUSION. ...................... 1-6CORROSION PREVENTION........................ 9-4

EEMISSION CONTROL WARRANTY .........................10-2ENGINE COOLANT .............7-23ENGINE COOLANT SOLUTION .............................2-5ENGINE IDLE SPEED INSPECTION........................7-19ENGINE OIL .................. 2-3,7-15

FFINAL GEAR OIL .................7-24FRONT WHEEL REMOVAL ............................7-35FUEL ......................................2-2FUEL HOSE .........................7-20FUEL SUPPLY CHECK..........8-2FUEL SYSTEM CHECK .........8-3FUEL TANK CAP .................3-17FUSES..................................7-42

GGEAR OIL...............................2-4GEARSHIFT LEVER ............3-18GENERAL LUBRICATION .......................7-5

HHELMET HOLDER ...............3-19

IIF A COLLISION IS IMMINENT, DO SOMETHING! .................. 1-3IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE ....... 1-3IGNITION SWITCH ................ 3-5IGNITION SYSTEM CHECK................................... 8-3INSPECTION AFTER CLEANING............................. 9-6INSPECTION BEFORE RIDING................................... 4-3INSPECTION BEFORE RIDING................................... 1-5INSTRUMENT PANEL........... 3-7

KKEY ........................................ 3-5KNOW YOUR LIMITS. ........... 1-4

LLEFT HANDLEBAR.............. 3-13LIGHT BULB REPLACEMENT .................. 7-39LOADING GUIDELINES ........ 6-4LOADING LIMIT ..................... 6-3LOCATION............................. 3-2LOCATION OF LABELS................................ 10-6LOCATION OF PARTS ................................... 3-2

MMAINTENANCE SCHEDULE ............................7-2MODIFICATION .....................6-4MOST ACCIDENTS CAN BE AVOIDED. ..............................1-2MOTORCYCLE CLEANING .............................9-5MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA) .......1-6

NNOTICE ..................................7-2

OON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....................10-5

PPRACTICE AWAY FROM TRAFFIC. ...............................1-5PROCEDURE FOR RETURNING TO SERVICE..........................9-3

RREAR BRAKE PEDAL ......... 3-18REAR WHEEL REMOVAL............................ 7-37REPORTING SAFETY DEFECTS............................. 10-4RIDING ON HILLS ................. 5-5RIGHT HANDLEBAR ........... 3-15

SSERIAL NUMBER LOCATION........................... 10-3SIDE STAND........................ 3-19SIDE STAND/IGNITION INTERLOCK SYSTEM......... 7-34SPARK PLUG ...................... 7-11SPECIAL SITUATIONS REQUIRE SPECIAL CARE. .................................... 1-4STARTING OFF AND SHIFTING............................... 5-3STARTING THE ENGINE.................................. 5-2STORAGE PROCEDURE ........................ 9-2SUSPENSION ADJUSTMENT ..................... 3-20

TTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED........................10-2THROTTLE CABLE ADJUSTMENT .....................7-20TIRES ...................................7-30TOOLS ...................................7-5

UUSING THE TRANSMISSION ....................5-4

Total page: 120

Top

1st cover4th cover

CMYK

Suzuki Red0

1001000

Suzuki Blue1007000

takumi color1000085

Black000

100

K 85%

M 70%

CM

YK

100%

4/1 (Cyan/Magenta/Yellow/Black/ )

99011-43H50-03A

VL

800/C/T

Part No. 99011-43H50-03A August, 2008 EN Printed in Japan

WARNINGFailure to follow these safetyprecautions may increase yourrisk of injury:

Wear a helmet, eye protec-tion, and bright protectiveclothing.Don’t ride after consumingalcohol or other drugs.Slow down on slippery sur-faces, unfamiliar terrain, orwhen visibility is reduced.Read owner’s manual care-fully.

VL800/C/ TOWNER’S MANUALThis owner’s manual containsimportant safety information.Please read it carefully.

TK

K9

4 mm

No.825 VL800/C/T (99011-43H50-03A)

Date post:	14-Feb-2019
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