Suzuki Intruder VL800 Supplementary Service Manual

Suzuki Intruder VL800 is a versatile motorcycle that combines power and style. With its 805cc V-twin engine, it delivers plenty of torque for a smooth and responsive ride. The Intruder VL800 is also equipped with a range of features that make it a pleasure to ride, including a comfortable seat, a low center of gravity, and a stylish design. Whether you're cruising down the highway or navigating city streets, the Suzuki Intruder VL800 is a great choice for riders of all levels.

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VL800 SERVICE MANUAL (99500-38043-01E)

9 9 5 0 1 - 3 8 0 8 0 - 0 1 E

VL800 K5.fm Page 3 Tuesday, June 15, 2004 12:04 PM

IMPORTANT

All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to

Environmental Protection agency emission regulations.

These regulations set specific standards for exhaust

requirements. This manual includes specific information required to properly inspect and service VL800 in accordance with all EPA regulations. It is strongly

Periodic Servicing and FI System and Fuel System be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA

program can be found in the U.S. SUZUKI EMISSION

CONTROL PROGRAM MANUAL/SERVICE BULLETIN.

VL800K5 (’05-MODEL) 1

VL800K5 (’05-MODEL)

This manual described the service specifications, service data, FI system and servicing procedurers which differ from those of the VL800K4 (’04-MODEL).

NOTE:

* Any differences between the VL800K4 (’04-MODEL) and VL800K5 (’05-MODEL) in specifications and service data are cleary indicated with an asterisk (*) mark.

* Please refer to the service manual for details which are not given in this manual.

SPECIFICATIONS .....................................................................................12- 2

ABBREVIATIONS USED IN THIS MANUAL ............................................12- 3

SAE-TO-FORMER SUZUKI TERM ...........................................................12- 5

SERVICE DATA.........................................................................................12- 7

PERIODIC MAINTENANCE CHART .........................................................12- 17

PRECAUTIONS IN SERVICING ................................................................12- 18

FI SYSTEM TECHNICAL FEATURES ......................................................12- 25

SELF-DIAGNOSIS FUNCTION .................................................................12- 30

FAIL-SAFE FUNCTION .............................................................................12- 34

FI SYSTEM TROUBLESHOOTING ...........................................................12- 35

SENSORS ..................................................................................................12- 90

FUEL DELIVERY SYSTEM .......................................................................12- 92

EMISSION CONTROL SYSTEMS .............................................................12-119

PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION

(Only for E-33)...........................................................................................12-124

TIGHTENING TORQUE .............................................................................12-125

WIRING HARNESS, CABLE AND HOSE ROUTING................................12-126

PAIR (AIR SUPPLY) SYSTEM DIAGRAM ................................................12-134

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .....................................12-135

EVAP CANISTER HOSE ROUTING (Only for E-33)................................12-136

SPECIAL TOOLS ......................................................................................12-137

WIRING DIAGRAM

COUNTRY AND AREA CODES

The following codes stand for the applicable country (-ies) and area (-s).

CODE

000

E-02

E-19

E-24

E-03

E-28

E-33

COUNTRY or AREA

Japan

U.K.

Australia

U.S.A. (Except for california)

Canada

California (U.S.A.)

EFFECTIVE FRAME NO.

---------------

JS1BM111200101117-

JS1BM111100112285-

JS1BM121300100613-

JS1VS55A 52100001-



2 VL800K5 (’05-MODEL)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................

2 510 mm (98.8 in)

Overall width .......................................................................................

985 mm (38.8 in)

Overall height ......................................................................................

1 100 mm (43.3 in)

Wheelbase ..........................................................................................

1 655 mm (65.2 in)

Ground clearance ...............................................................................

140 mm ( 5.5 in)

Seat height. .........................................................................................

700 mm (27.6 in)

Dry mass .............................................................................................

*246 kg (542 lbs)

ENGINE

Type ....................................................................................................

4-stroke, Liquid-cooled, OHC

Number of cylinders ............................................................................

Bore ....................................................................................................

83 mm (3.268 in)

Stroke..................................................................................................

74.4 mm (2.929 in)

Displacement ......................................................................................

805 cm

(49.1 cu. in)

Compression ratio ...............................................................................

9.4 : 1

Fuel system.........................................................................................

*Fuel injection

Air cleaner ...........................................................................................

Non-woven fabric element

Starter system .....................................................................................

Electric

Lubrication system ..............................................................................

Wet sump

Idle speed ...........................................................................................

1 100 ± 100 r/min

DRIVE TRAIN

Clutch..................................................................................................

Wet multi-plate type

Transmission.......................................................................................

5-speed constant mesh

Gearshift pattern .................................................................................

1-down, 4-up

Primary reduction ratio ........................................................................

1.690 (71/42)

Secondary reduction ...........................................................................

1.000 (30/30)

Gear ratios, Low..................................................................................

2.461 (32/13)

2nd ..................................................................................

1.631 (31/19)

3rd ...................................................................................

1.227 (27/22)

CHASSIS

4th ...................................................................................

1.000 (25/25)

Top ..................................................................................

0.814 (22/27)

Final reduction ratio ............................................................................

3.503 (17/15 × 34/11)

Drive system .......................................................................................

Shaft drive

Front suspension ................................................................................

Telescopic, coil spring, oil damped

Rear suspension .................................................................................

Link type, coil spring, oil damped

Front suspension stroke......................................................................

140 mm (5.5 in)

Rear wheel travel. ...............................................................................

Caster .................................................................................................

30° 20’

Trail .....................................................................................................

141 mm (5.55 in)

Steering angle .....................................................................................

38° (right & left)

Turning radius .....................................................................................

3.0 m (9.8 ft)

Front brake..........................................................................................

Disc brake

Drum brake

130/90-16 M/C 67H, tube type

Rear tire size .......................................................................................

170/80-15 M/C 77H, tube type

ELECTRICAL

Ignition type.........................................................................................

Electronic ignition (Transistorized)

Ignition timing. .....................................................................................

5° B.T.D.C. at 1 100 r/min

Spark plug ...........................................................................................

NGK DPR7EA-9 or DENSO X22EPR-U9

Battery.................................................................................................

12V 36 kC (10 Ah) /10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse ............................................................................................

30A

Fuse ....................................................................................................

*15/10/10/10/10/10A

Headlight .............................................................................................

12V 60W/55W (H4)

Position/Parking light ..........................................................................

*12V 5W........ E-02, 19

Brake light/Taillight..............................................................................

12V 21/5W

Front turn signal light ..........................................................................

12V 21/5W .... E-02, 19, 24

12V 21/5W.... E-03, 28, 33

Rear turn signal light ...........................................................................

12V 21W

Speedometer light ...............................................................................

LED

Turn signal indicator light ....................................................................

LED

Neutral indicator light ..........................................................................

LED

High beam indicator light ....................................................................

LED

*Fuel indicator light .............................................................................

LED

Oil pressure/Water temperature/FI warning light ................................

LED

CAPACITIES

Fuel tank ..........................................................................................

*15.5 L (4.1/3.4 US/Imp gal)

Engine oil, oil change .........................................................................

3 000 ml (3.2/2.6 US/Imp qt) with filter change...............................................................

3 400 ml (3.6/3.0 US/Imp qt) overhaul. ...........................................................................

3 700 ml (3.9/3.3 US/Imp qt)

Final gear oil .......................................................................................

200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)

These specifications are subject to change without notice.

VL800K5 (’05-MODEL) 3

ABBREVIATIONS USED IN THIS

MANUAL

A

ABDC

ACL

API

: After Bottom Dead Center

: Alternating Current

: Air Cleaner, Air Cleaner Box

: American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure: Atmospheric Pressure

: Atmospheric Pressure sensor

A/F

(APS, AP Sensor)

: Air Fuel Mixture

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

: Evaporative Emission EVAP

EVAP Canister: Evaporative Emission

Canister (Canister)

B

BBDC : Before Bottom Dead Center

F

FI : Fuel Injection, Fuel Injector

BTDC

B+

: Before Top Dead Center

: Battery Positive Voltage

FPR

: Fuel Pump

: Fuel Pressure Regulator

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

D

CPU

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

GND

GP Switch

H

: Carbon Monoxide

: Central Processing Unit

: Direct Current

: Gear Position Switch

: Hydrocarbons

HO2 sensor : Heated Oxygen Sensor (HO2S)

I

G

GEN

FP Relay : Fuel Pump Relay

: Generator

: Ground

DMC : Dealer Mode Coupler

IAP Sensor : Intake Air Pressure Sensor (IAPS)

DOHC : Double Over Head Camshaft

IAT Sensor : Intake Air Temperature Sensor

DRL : Daytime Running Light

(IATS)

IG : Ignition

L

LCD

LED

: Liquid Crystal Display

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand LH

4 VL800K5 (’05-MODEL)

M

MAL-Code

Max

MIL

: Malfunction Code

(Diagnostic Code)

: Maximum

: Malfunction Indicator Lamp

(LED)

: Minimum Min

N

NOX : Nitrogen Oxides

O

OHC

OPS

: Over Head Camshaft

: Oil Pressure Switch

P

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

R

S

ROM

SAE

: Right Hand

: Read Only Memory

: Society of Automotive Engineers

SDS : Suzuki Diagnosis System

STC System : Secondary Throttle Control System

(STCS)

STP Sensor : Secondary Throttle Position Sensor

(STPS)

ST Valve : Secondary Throttle Valve (STV)

STV Actuator : Secondary Throttle Valve Actuator

(STVA)

T

TO Sensor

TP Sensor

: Tip-Over Sensor (TOS)

: Throttle Position Sensor (TPS)

VL800K5 (’05-MODEL) 5

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

Air Cleaner

SAE TERM

FULL TERM

Barometric Pressure

ABBREVIATION

ACL

BARO

FORMER SUZUKI TERM

Air Cleaner, Air Cleaner Box

B+

Barometric Pressure, Atmospheric

Pressure (APS, AP Sensor)

Battery Voltage, +B Battery Positive Voltage

Camshaft Position Sensor

Crankshaft Position Sensor

CMP Sensor

CKP Sensor

Camshaft Position Sensor (CMPS)

Crankshaft Position Sensor (CKPS),

Crank Angle

Data Link Connector

Diagnostic Test Mode

Diagnostic Trouble Code

Electronic lgnition

Engine Control Module

Engine Coolant Level

Engine Coolant Temperature

ECM

ECL

ECT

DLC

DTM

DTC

Dealer Mode Coupler

-------

Diagnostic Code, Malfunction Code

-------

Engine Control Module (ECM)

FI Control Unit, Engine Control Unit (ECU)

Coolant Level

Coolant Temperature, Engine Coolant Temper-

EOT

RPM

EVAP

EVAP Canister ature, Water Temperature

Oil Temorature, Engine Oil Tempereture

Engine Speed (RPM)

Evaporative Emission

------- (Canister)

Engine Oil Temperature

Engine Speed

Evaporative Emission

Evaporative Emission Canister

Fan Control

Fuel Level Sensor

Fuel Pump

Generator

Ground

Heated Ocygen Sensor

-------

GEN

GND

HO2S

-------

Fuel Level Sensor, Fuel Level Gauge

Fuel Pump (FP)

Generator

Ground (GND, GRD)

Heated Oxygen Sensor (HO2S), O2 Sensor

6 VL800K5 (’05-MODEL)

SAE TERM

FULL TERM

Idle Speed Control

Ignition Control

Ignition Control Module

Intake Air Temperature

Malfunction Indicator Lamp

ABBREVIATION

ISC

ICM

IAT

FORMER SUZUKI TERM

-------

Electronic Spark Advance (ESA)

-------

Intake Air Temperature (IAT), Air Temperature

Manifold Absolute Pressure

Mass Air Flow

On-Board Diagnostic

MIL

MAP

MAF

Open Loop

Programmable Read Only Memory

Pulsed Secondary Air Injection

Purge Valve

Random Access Memory

Read Only Memory

Secondary Air Injection

Secondary Throttle Control System

Secondary Throttle Valve

Secondary Throttle Valve Actuator

Throttle Body

Throttle Body Fuel Injection

Throttle Position Sensor

Voltage Regulator

Volume Air Flow

AIR

STCS

STV

STVA

TBI

TP Sensor

VAF

LED Lamp

Malfunction Indicator Lamp (MIL)

Intake Air Pressure (IAP), Intake Vacuum

Air Flow

OBD Self-Diagnosis Function

Diagnostic

PROM

PAIR

-------

Purge Valve

Pulse Air Control (PAIR)

-------

ROM

-------

STC System (STCS)

ST Valve (STV)

STV Actuator (STVA)

Throttle Body (TB)

Throttle Body Fuel Injection (TBI)

TP Sensor (TPS)

Voltage Regulator

Air Flow

VL800K5 (’05-MODEL) 7

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance (when cold)

Valve guide to valve stem clearance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

STANDARD

(1.18)

(1.02)

0.08 – 0.13

(0.003 – 0.005)

0.17 – 0.22

(0.007 – 0.009)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0022)

5.500 – 5.512

(0.2165 – 0.2170)

IN.

EX.

IN. & EX.

5.475 – 5.490

(0.2156 – 0.2161)

5.455 – 5.470

----

0.9 – 1.1

IN. & EX.

(0.035 – 0.043)

Valve head radial runout

IN. & EX.

----

Valve spring free length

INNER ----

OUTER

Valve spring tension

INNER

----

64 – 73 N (6.51 – 7.49 kgf)

(14.35 – 16.51 lbs) at length 32.5 mm (1.28 in)

119 – 136 N (12.09 – 13.91 kgf)

(26.65 – 30.67 lbs) at length 36.0 mm (1.42 in)

OUTER

Unit: mm (in)

LIMIT

----

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

3.1

(0.12)

----

0.03

(0.001)

38.3

(1.51)

40.1

(1.58)

----

8 VL800K5 (’05-MODEL)

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Camshaft runout

Cylinder head distortion

Cylinder head cover distortion

Front

Rear

IN.

EX.

IN.

EX.

Rear left side

Front right side

Rear right side

Front left side

Rear left side

Front right side

STANDARD

35.95 – 35.99

(1.415 – 1.417)

36.92 – 36.96

(1.454 – 1.455)

35.50 – 35.54

(1.398 – 1.399)

36.52 – 36.62

(1.438 – 1.442)

0.032 – 0.066

(0.0013 – 0.0026)

20.012 – 20.025

(0.7879 – 0.7884)

25.012 – 25.025

(0.9847 – 0.9852)

19.959 – 19.980

(0.7858 – 0.7866)

Rear right side

Front left side

----

24.959 – 24.980

(0.9826 – 0.9835)

----

STANDARD ITEM

Compression pressure

1 300 – 1 700 kPa

(13 – 17 kgf/cm², 185 – 242 psi)

Compression pressure difference ----

Piston to cylinder clearance

Cylinder bore

Piston diam.

Cylinder distortion

0.045 – 0.055

(0.0018 – 0.0022)

83.000 – 83.015

(3.2677 – 3.2683)

82.950 – 82.965

(3.2657 – 3.2663)

Measure at 15 mm (0.6 in) from the skirt end.

----

Unit: mm (in)

LIMIT

35.65

(1.404)

36.62

(1.442)

35.20

(1.386)

36.28

(1.428)

0.150

(0.0059)

----

0.10

(0.004)

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

1 100 kPa

(11 kgf/cm²

156 psi)

200 kPa

(2 kgf/cm²

28 psi)

0.120

(0.0047)

83.085

(3.2711)

82.880

(3.2630)

0.05

(0.002)

ITEM

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

1st

2nd R

1st

2nd

1st

STANDARD

Approx. 9.6 (0.38)

Approx. 11.8 (0.46)

0.20 – 0.35

(0.008 – 0.014)

0.20 – 0.35

(0.008 – 0.014)

----

2nd ----

Piston ring groove width

1st

2nd

1.01 – 1.03

(0.0398 – 0.0406)

1.21 – 1.23

(0.0476 – 0.0484)

Piston pin bore

2.51 – 2.53

Piston ring thickness

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Oil

1st

(0.0988 – 0.0996)

0.970 – 0.990

1.170 – 1.190

(0.0461 – 0.0469)

2nd

20.002 – 20.008

(0.7875 – 0.7877)

19.992 – 20.000

(0.7871 – 0.7874)

STANDARD

Conrod small end I.D.

Conrod big end side clearance

Conrod big end width

Crank pin width

Conrod big end oil clearance

Crank pin O.D.

Crankshaft journal oil clearance

20.010 – 20.018

(0.7878 – 0.7881)

0.10 – 0.20

(0.004 – 0.008)

21.95 – 22.00

(0.864 – 0.866)

22.10 – 22.15

(0.870 – 0.872)

0.024 – 0.042

(0.0009 – 0.0017)

40.982 – 41.000

(1.6135 – 1.6142)

0.020 – 0.050

(0.0008 – 0.0020)

47.965 – 47.980

(1.8884 – 1.8890)

Crankshaft journal O.D.

VL800K5 (’05-MODEL) 9

----

20.030

(0.7886)

19.980

(0.7866)

Unit: mm (in)

LIMIT

20.040

(0.7890)

0.30

(0.012)

----

0.080

(0.0031)

----

0.080

(0.0031)

----

LIMIT

7.7

(0.30)

9.4

(0.37)

0.70

(0.028)

0.70

(0.028)

0.180

(0.007)

0.150

(0.006)

----

10 VL800K5 (’05-MODEL)

ITEM

Crankshaft thrust bearing thickness

Crankshaft thrust clearance

Crankshaft runout

STANDARD

1.925 – 2.175

(0.0758 – 0.0856)

0.05 – 0.10

(0.002 – 0.004)

----

LIMIT

----

0.05

(0.002)

OIL PUMP

ITEM

Oil pressure (at 60 °C, 140 °F)

STANDARD

350 – 600 kPa

(3.5 – 6.5 kgf/cm², 50 – 92 psi) at 3 000 r/min.

LIMIT

----

CLUTCH

Clutch lever play

ITEM

Clutch release screw

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

TRANSMISSION

ITEM

Primary reduction ratio

Secondary reduction ratio

Final reduction ratio

Gear ratios

Shift fork to groove clearance

Low

2nd

3rd

4th

Top

STANDARD

10 – 15

(0.4 – 0.6)

No. 1

1/4 turn back

2.92 – 3.08

49.2

3.42 – 3.58

No. 2

(0.135 – 0.141)

15.9 – 16.0

(0.626 – 0.630)

----

(1.94)

No.1

Unit: mm (in) Except ratio

STANDARD

1.690 (71/42)

1.133 (17/15)

3.090 (34/11)

2.461 (32/13)

1.631 (31/19)

1.227 (27/22)

1.000 (25/25)

0.814 (22/27)

0.10 – 0.30

(0.004 – 0.012)

0.10 – 0.30

(0.004 – 0.012)

LIMIT

----

0.50

(0.020)

0.50

(0.020)

No.2

Unit: mm (in)

LIMIT

----

2.62

(0.103)

3.12

(0.123)

15.1

(0.594)

0.10

(0.004)

46.8

(1.84)

VL800K5 (’05-MODEL) 11

ITEM

Shift fork groove width

Shift fork thickness

No.1

No.2

No.1

No.2

STANDARD

5.50 – 5.60

(0.217 – 0.220)

4.50 – 4.60

(0.177 – 0.181)

5.30 – 5.40

(0.209 – 0.213)

4.30 – 4.40

(0.169 – 0.173)

LIMIT

----

SHAFT DRIVE

ITEM

Secondary bevel gear backlash

Final bevel gear backlash

Damper spring free length

Drive side

STANDARD

0.05 – 0.32

(0.002 – 0.013)

0.03 – 0.064

(0.001 – 0.025)

----

THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT

ITEM

temperature

Thermostat valve opening

Thermostat valve lift

ECT sensor resistance

Approx. 75 °C (167 °F)

20 °C

(68 °F)

40 °C

(104 °F)

60 °C

* Approx. 2.45 k

Ω

* Approx. 1.148 k

Ω

* Approx. 0.587 k

Ω

(140 °F)

80 °C

(176 °F)

* Approx. 0.322 k

Ω

Radiator cap valve opening pressure

Cooling fan thermo-switch operating temperature

Engine coolant type

95 – 125 kPa

(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)

OFF

→ON

→OFF

Approx. 105 °C (221 °F)

Approx. 100 °C (212 °F)

Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of

50:50.

1 500 ml

(1.6/1.3 US/lmp qt)

Engine coolant capacity

Unit: mm (in)

LIMIT

----

58.5

(2.30)

NOTE

----

12 VL800K5 (’05-MODEL)

* INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

ITEM

* Injector resistance

* Fuel pump discharge amount

SPECIFICATION

11 – 13

Ω at 20 °C (68 °F)

Approx. 168 ml (5.7/5.9 US/lmp oz) and more/10 sec.

* Fuel pressure regulator operating set pressure

Approx. 300 kPa (3.0 kgf/cm², 43 psi)

* FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR

ITEM

* CKP sensor resistance

SPECIFICATION

184 – 276

Ω

* CKP sensor peak voltage

4.0 V and more

* IAP sensor input voltage

* IAP sensor output voltage

* TP sensor input voltage

* TP sensor resistance

* TP sensor output voltage

* ECT sensor input voltage

* ECT sensor resistance

* IAT sensor input voltage

* IAT sensor resistance

* TO sensor resistance

* TO sensor voltage

* GP switch voltage

* Injector voltage

* STP sensor input voltage

* STP sensor resistance

* STP sensor output voltage

* STV actuator resistance

4.5 – 5.5 V

Approx. 2.6 V at idle speed

4.5 – 5.5 V

Closed Approx. 1.1 k

Ω

Opened

Closed

Opened

Approx. 4.3 k

Ω

Approx. 1.1 V

4.5 – 5.5 V

Normal

Leaning

Approx. 2.45 k

Ω at 20 °C (68 °F)

4.5 – 5.5 V

Ω at 20 °C (68 °F)

19.1 – 19.7 k

Ω

0.4 – 1.4 V

3.7 – 4.4 V

0.6 V and more

Closed

Opened

Closed

Opened

Battery voltage

4.5 – 5.5 V

Approx. 0.5 k

Ω

Approx. 3.9 k

Ω

Approx. 0.5 V

Approx. 3.9 V

Approx. 6.5

Ω

NOTE

When cranking

When leaning 65 °

From 1st to

Top

VL800K5 (’05-MODEL) 13

* THROTTLE BODY

ITEM

Bore size

I.D. No.

Idle r/min.

Fast idle r/min.

Throttle cable play

SPECIFICATION

* 34 mm

* 41F1 (For E-33), 41F0 (For the others)

* 1 100 ± 100 r/min.

* 2 100 r/min. (When cold engine)

2.0 – 4.0 mm

(0.08 – 0.16 in)

ELECTRICAL

ITEM

Firing order

SPECIFICATION

1·2

Spark plug

Type

Gap

NGK: DPR7EA-9

DENSO: X22EPR-U9

0.8 – 0.9

(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.

* CKP sensor resistance 184 – 276

Ω

* CKP sensor peak voltage

* Ignition coil resistance

* Ignition coil primary peak voltage

Generator no-load voltage

Generator coil resistance

Primary

4.0 V and more

Ω

24 – 36 k

Ω

Secondary

200 V and more

0.2 – 1.5

Ω

70 V (AC) and more at 5 000 r/min.

(when engine is cold)

Regulated voltage

Generator maximum output

Starter relay resistance

GP switch voltage

Battery Type designation

Capacity

Fuse size

Headlight

Signal

Ignition

Meter

Main

Power source

14.0 – 15.5 V at 5 000 r/min.

375 W at 5 000 r/min

3 – 7

Ω

0.6 V and more (From 1st to top without neutral)

FTX12-BS

12 V 36 kC (10 Ah)/10 HR

10 A

15 A

10 A

30 A

10 A

Unit: mm (in)

NOTE

Terminal –

Terminal

Plug cap –

Terminal

+ B/Y

Front

- O/W

+ W

Rear

- O/W

Y – Y

14 VL800K5 (’05-MODEL)

WATTAGE

Headlight

ITEM

Position/Parking light

Brake light/Taillight

Turn signal light

Speedometer light

Engine coolant temp. warning light

Turn signal indicator light

High beam indicator light

Neutral indicator light

Oil pressure indicator light

E-03, 28, 33

60 W

55 W

21/5 W

21/5 W (Front),

21 W (Rear)

LED

SPECIFICATION

E-24

←

21 W

←

BRAKE + WHEEL

ITEM

Rear brake pedal free travel

Rear brake pedal height

Brake drum I.D.

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

Brake caliper piston diam.

Brake fluid type

Wheel rim runout

Rear

Front

STANDARD

20 – 30

(0.8 – 1.2)

75 – 85

(3.0 – 3.3)

----

4.8 – 5.2

(0.19 – 0.21)

----

12.700 – 12.743

(0.5000 – 0.5017)

Front

12.657 – 12.684

(0.4983 – 0.4993)

30.230 – 30.306

(1.1901 – 1.1931)

30.150 – 30.200

(1.1870 – 1.1889)

DOT 4

Axial ----

Radial

Front

Rear

----

J16 M/C × MT 3.00

J15 M/C × MT 4.00

Wheel rim size

Unit: W

Others

←

4 W

←

----

2.0

(0.08)

2.0

(0.08)

----

Unit: mm (in)

LIMIT

----

180.7

(7.11)

4.5

(0.18)

0.30

(0.012)

----

VL800K5 (’05-MODEL) 15

TIRE

ITEM

Cold inflation tire pressure

(Solo riding)

Cold inflation tire pressure

(Dual riding)

Tire size

Tire type

Tire tread depth

Front

Rear

Front

Rear

Front

Rear

Front

Rear

Front

Rear

STANDARD

200 kPa

(2.00 kgf/cm², 29 psi)

250 kPa

(2.50 kgf/cm², 36 psi)

200 kPa

(2.00 kgf/cm², 29 psi)

250 kPa

(2.50 kgf/cm², 36 psi)

130/90 – 16 M/C 67H

170/80 – 15 M/C 77H

IRC GS-23F

IRC GS-23R

----

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

(5.51)

(21.73)

140

551.7

Front fork oil level (without spring)

Front fork oil capacity (each leg)

177

(6.96)

SUZUKI FORK OIL SS-08 or an equivalent fork oil Front fork oil type

412 ml

(24.0/25.0 US/Imp oz)

Front fork inner tube outside diam.

(1.61)

Front fork spring adjuster

Rear shock absorber spring adjuster

Rear wheel travel

----

(4)

105

(4.13)

Swingarm pivot shaft runout

----

Unit: mm (in)

LIMIT

----

540.6

(21.29)

----

0.3

(0.01)

LIMIT

----

1.6

(0.06)

2.0

(0.08)

16 VL800K5 (’05-MODEL)

FUEL + OIL

ITEM

Fuel type

Fuel tank capacity

Engine oil type

Engine oil capacity

Final bevel gear oil type

Final bevel gear oil capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method.

Gasoline containing MTBE (Methyl Tertiary Butyl

Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended.

Including reserve

Fuel level indicator light lighting

17.0 L

(4.5/3.7 US/lmp gal)

1.5 L

(0.4/0.3 US/lmp gal)

SAE 10 W-40, API, SF or SG

3 000 ml

Change

Filter change

(3.2/2.6 US/lmp qt)

3 400 ml

3 700 ml

Overhaul

(3.9/3.3 US/lmp qt)

SAE 90 hypoid gear oil with

GL-5 under API classification

200 – 220 ml

(6.8/7.0 – 7.4/7.7 US/lmp oz)

NOTE

E-03, 28, 33

Others

VL800K5 (’05-MODEL) 17

PERIODIC MAINTENANCE CHART

Item

Air cleaner element

Spark plug

Valve clearance

Engine oil

Engine oil filter

Fuel line

Idle speed

*Throttle valve synchronization

Interval miles 600 km 1 000 months 2

----

4 000

6 000

7 500

12 000

11 000

18 000

----

I I I

Replace fuel hose every 4 years.

I I I

---I ----

(E-33 only)

------I ----

Replace vapor hose every 4 years.

----

I I

I ----

Evaporative emission control system

(E-33 only)

PAIR (air supply) system

Throttle cable play

Clutch cable play

Radiator hose

Engine coolant

Final gear oil

Brake

Brake hose

Brake fluid

Tire

Steering

Front fork

Rear suspension

----

Replace every 4 years.

Replace every 2 years.

----

Replace every 2 years.

---I

----

I I

----

Exhaust pipe bolts and muffler bolt and nut

Chassis bolt and nut

----

NOTE:

I=Inspect and clean, adjust, replace or lubricate as necessary;

R=Replace; T=Tighten

14 500

24 000

----

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months).

NOTE:

Warm up the engine before adjusting the engine idle speed.

• Start the engine, turn the throttle stop screw

1 and set the engine idle speed as follows.

• Connect the multit tester to the high-tension cord.

! Engine idle speed: 1 100 ± 100 r/min

" 09900-26006: Engine tacho tester set

18 VL800K5 (’05-MODEL)

PRECAUTIONS IN SERVICING

When handling the component parts or servicing the FI system, observe the following points for the safety of the system.

ELECTRICAL PARTS

CONNECTOR/COUPLER

• When connecting a connector, be sure to push it in until a click is felt.

• With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.

• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.

• Inspect each terminal on the connector/coupler for looseness or bending.

• Inspect each terminal for corrosion and contamination.

which could impede proper terminal contact.

The terminals must be clean and free of any foreign material

replace.

by hand lightly. If any abnormal condition is found, repair or

Click

• When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler.

1 Coupler

2 Probe

Click

• When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open.

Connect the probe as shown to avoid opening of female terminal.

Never push in the probe where male terminal is supposed to fit.

• Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.

1 Coupler

2 Probe

3 Where male terminal fits

FUSE

• When a fuse blows, always investigate the cause to correct it and then replace the fuse.

• Do not use a fuse of a different capacity.

• Do not use wire or any other substitute for the fuse.

ECM/VARIOUS SENSORS

• Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation.

INCORRECT

• Be careful not to touch the electrical terminals of the ECM.

The static electricity from your body may damage this part.

VL800K5 (’05-MODEL) 19

20 VL800K5 (’05-MODEL)

• When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch

1, or electronic parts may get damaged.

• Battery connection in reverse polarity is strictly prohibited.

Such a wrong connection will damage the components of the

FI system instantly when reverse power is applied.

• Removing any battery terminal of a running engine is strictly prohibited.

The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in serious damage.

• Before measuring voltage at each terminal, check to make

sure that battery voltage is 11 V or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagnosis.

• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECM when its coupler is disconnected.

Otherwise, damage to ECM may result.

• Never connect an ohmmeter to the ECM with its coupler connected. If attempted, damage to ECM or sensors may result.

• Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

INCORRECT

VL800K5 (’05-MODEL) 21

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE

While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

• Loose connection of connector/coupler.

• Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.)

• Wire harness being open.

• Poor terminal-to-wire connection.

• Disconnect the negative cable from the battery.

• Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped.

1 Sensor

2 ECM

*1 Check for loose connection.

• Using a test male terminal, check the female terminals of the circuit being checked for contact tension.

Check each terminal visually for poor contact (possibly

the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

If contact tension is not enough, rectify the contact to increase

*1 tension or replace.

The terminals must be clean and free of any foreign material which could impede proper terminal contact.

*1 Check contact tension by inserting and removing.

*2 Check each terminal for bend and proper alignment.

• Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any.

A Looseness of crimping

B Open

C Thin wire (a few strands left)

22 VL800K5 (’05-MODEL)

Continuity check

• Measure resistance across coupler

B (between A and C in the figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals

A and C.

1 ECM

• Disconnect the coupler

B and measure resistance between couplers

A and B.

If no continuity is indicated, the circuit is open between couplers

A and B. If continuity is indicated, there is an open circuit between couplers

B’ and C or an abnormality in coupler

B’ or coupler C.

1 ECM

VOLTAGE CHECK

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

• With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground.

If measurements were taken as shown in the figure at the right and results are as listed below, it means that the circuit is open

between terminals

A and B.

Voltage Between:

C and body ground: Approx. 5 V

B and body ground: Approx. 5 V

A and body ground:

0 V

Also, if measured values are as listed below, a resistance

(abnormality) exists which causes the voltage drop in the circuit between terminals

A and B.

Voltage Between:

C and body ground: Approx. 5 V

B and body ground: Approx. 5 V

A and body ground:

3 V

2 V voltage drop

0 V

5 V

SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.

• Disconnect the connectors/couplers at both ends of the circuit to be checked.

NOTE:

If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled.

• Measure resistance between terminal at one end of circuit (

A terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals

A and C.

1 Other parts

*1 To other parts.

VL800K5 (’05-MODEL) 23

• Disconnect the connector/coupler included in circuit (coupler

B) and measure resistance between terminal A and body

ground.

If continuity is indicated, the circuit is shorted to the ground between terminals

A and B.

*1 To other parts.

5 V

24 VL800K5 (’05-MODEL)

USING THE MULTI-CIRCUIT TESTER

• Use the Suzuki multi-circuit tester set (09900-25008).

• Use well-charged batteries in the tester.

• Be sure to set the tester to the correct testing range.

USING THE TESTER

• Incorrectly connecting the

+ and - probes may cause the inside of the tester to burnout.

• If the voltage and current are not known, make measurements using the highest range.

• When measuring the resistance with the multi-circuit tester

∞ will be shown as 10.00 MΩ and “1” flashes in the display.

• Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.

• After using the tester, turn the power off.

" 09900-25008: Multi-circuit tester set

NOTE:

* When connecting the multi-circuit tester, use the needle connect the probes of tester to them.

* Use the needle pointed probe to prevent the rubber of the water proof coupler from damage.

VL800K5 (’05-MODEL) 25

FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)

The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations.

These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

ECM

Intake Air Pressure

Sensor (IAP Sensor)

Crankshaft Position

Sensor (CKP Sensor)

Throttle Position

Sensor (TP Sensor)

Various

Sensors

Injectors

Intake air pressure signal

Engine speed signal

Throttle opening signal

Basic fuel injection time

Various signals

Injection signal

Compensation

Ultimate fuel injection time

26 VL800K5 (’05-MODEL)

COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel injection time (volume).

SIGNAL

ENGINE COOLANT TEMPERATURE SEN-

SOR SIGNAL

INTAKE AIR TEMPERATURE SENSOR

SIGNAL

BATTERY VOLTAGE SIGNAL

ENGINE RPM SIGNAL

STARTING SIGNAL

DESCRIPTION

When engine coolant temperature is low, injection time (volume) is increased.

When intake air temperature is low, injection time (volume) is increased.

ECM operates on the battery voltage and at the same time, it monitors the voltage signal for compensation of the fuel injection time (volume). A longer injection time is needed to adjust injection volume in the case of low voltage.

At high speed, the injection time (volume) is increased.

When starting engine, additional fuel is injected during cranking engine.

ACCELERATION SIGNAL/

DECELERATION SIGNAL

During acceleration, the fuel injection time (volume) is increased in accordance with the throttle opening speed and engine rpm. During deceleration, the fuel injection time (vol-

SIGNAL

TIP-OVER SENSOR SIGNAL

(FUEL SHUT-OFF)

OVER-REV. LIMITER SIGNAL ume) is decreased.

INJECTION STOP CONTROL

DESCRIPTION

When the motorcycle tips over, the tip-over sensor sends a signal to the ECM. Then, this signal cuts OFF current sup-

plied to the fuel pump, fuel injectors and ignition coils.

The fuel injectors stop operation when engine rpm reaches rev. limit rpm.

FI SYSTEM PARTS LOCATION

D E

ECM

A IAP sensor (Rear cylinder)

B Ignition coil No.1 (Rear cylinder)

C ECT sensor

D Fuel injector (Rear cylinder)

E Fuel injector (Front cylinder)

F PAIR control solenoid valve

G CKP sensor

H GP switch

I FP relay

VL800K5 (’05-MODEL) 27

28 VL800K5 (’05-MODEL)

J HO2 sensor

K TO sensor

L STVA

M Speedometer

ECM

N STP sensor

O TP sensor

P IAP sensor (Front cylinder)

Q Ignition coil No.2 (Front cylinder)

FI SYSTEM WIRING DIAGRAM

VL800K5 (’05-MODEL) 29

30 VL800K5 (’05-MODEL)

SELF-DIAGNOSIS FUNCTION

The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and

“Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI light). To check the function of the individual FI system devices, the dealer mode is prepared. In this check, the special tool is necessary to read the code of the malfunction items.

USER MODE

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

Odometer (Tripmeter)

Odometer and “FI” letters

*1 Engine can start

Engine can not start “FI” letter

FI LIGHT

INDICATION b

----

FI light turns ON.

FI light turns ON and blinks.

INDICATION MODE

----

Each 2 sec. Odometer and “FI” is indicated alternately.

“FI” is indicated continuously.

*1 run.

When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, “FI” and odometer are indicated in the LCD panel and motorcycle can

The injection signal is stopped, when the crankshaft position

#1 and #2 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, “FI” is indicated in

“CHEC”: The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 3 seconds.

For Example

: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from ECM, and the panel indicates “CHEC”.

If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers.

The possible cause of this indication is as follows;

Engine stop switch is in OFF position. Side-stand/ignition inter-lock system is not working. Ignition fuse is burnt.

NOTE:

Until starting the engine, the FI light turns ON.

The FI light is also turned ON when engine temperature is high or oil pressure is low.

VL800K5 (’05-MODEL) 31

DEALER MODE

The defective function is memorized in the computer. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

" 09930-82720: Mode select switch

If the couplers from the ECM are disconnected, the malfunction code memory is erased and the malfunction code can not be checked.

MALFUNCTION

“NO”

“YES”

LCD (DISPLAY)

INDICATION

C00

C**code is indicated from small numeral to large one.

FI LIGHT INDICATION

FI light turns OFF.

INDICATION MODE

----

For each 2 sec., code is indicated.

32 VL800K5 (’05-MODEL)

CODE

C24

C25

C28

C29

C31

C32

C33

C41

C00

C12

C13

C14

C15

C17

C21

C23

C42

C44

C49

MALFUNCTION PART

None

Crankshaft position sensor (CKPS)

Intake air pressure sensor (IAPS)

Throttle position sensor (TPS)

Engine coolant temperature sensor (ECTS)

Intake air pressure sensor (IAPS)

Intake air temperature sensor (IATS)

Tip-over sensor (TOS)

Ignition signal #1 (IG coil #1)

Ignition signal #2 (IG coil #2)

Secondary throttle valve actuator (STVA)

Secondary throttle position sensor (STPS)

Gear position signal (GP switch)

Injector signal #1 (FI #1)

Injector signal #2 (FI #2)

Fuel pump control system (FP control system)

Ignition switch signal (IG switch signal)

Heated oxygen sensor (HO2S)

PAIR control solenoid valve

REMARKS

No defective part

Pick-up coil signal, signal generator

For Front cylinder

For Rear cylinder

For Front cylinder

For Rear cylinder

For Front cylinder

Fuel pump, Fuel pump relay

Anti-theft

For E-02, 19, 24

To get the proper signal from the throttle position sensor, the sensor basic position is indicated in the LCD

(DISPLAY) panel. The malfunction code is indicated in three digits. In front of the three digits, a line appears

1 100 rpm, slightly turn the throttle position sensor and bring the line to middle.

In the normal condition, the throttle valve stop screw pushes throttle valves slightly, and indication point is middle line.

When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to

ECM. In this case, C28 and C29 are indicated alternately.

TPS ADJUSTMENT

1. Lift and support the fuel tank. (

$Page 93)

2. Adjust the engine rpm to 1 100 rpm.

NOTE:

Warm up the engine before adjustment.

3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness.

4. If the throttle position sensor adjustment is necessary, loosen the screw and turn the throttle position sensor

1 and bring the line to middle.

5. Then, tighten the screw to fix the throttle position sensor.

" 09930-82720: Mode select switch

position, where it is fixed.

The LCD indicates 0.4 sec./time, and two times show the correct

A Incorrect

B Correct position

VL800K5 (’05-MODEL) 33

34 VL800K5 (’05-MODEL)

FAIL-SAFE FUNCTION

FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.

ITEM FAIL-SAFE MODE

STARTING

ABILITY

RUNNING

ABILITY

IAP sensor

TP sensor

ECT sensor

IAT sensor

Ignition signal

Intake air pressure is fixed to 760 mmHg.

The throttle opening is fixed to full open position.

Ignition timing is also fixed.

Engine coolant temperature value is fixed to 80 °C (176 °F).

Intake air temperature value is fixed to 40 °C (104 °F).

#1 Ignition-off

“YES”

“YES” “YES”

Front cylinder can run.

Injection signal

Secondary throttle valve actuator

STP sensor

Gear position signal

#2 Ignition-off “YES” “YES”

Rear cylinder can run.

gear.

#1 Fuel-cut

#2 Fuel-cut

Secondary throttle valve is fixed to

connection or lock occurs, power from ECM is shut off.

full close position.

Gear position signal is fixed to 5th

“YES”

Rear cylinder can run.

“YES”

“YES” “YES”

Fuel-air compensation ratio is fixed to normal condition.

“YES” “YES”

Heated oxygen sensor

(E-02, 19, 24)

PAIR control solenoid valve ECM stops controlling PAIR control solenoid valve.

“YES” “YES”

The engine can start and can run even if the above signal is not received from each sensor. But, the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In this case, it is necessary to bring the motorcycle to the workshop for complete repair.

VL800K5 (’05-MODEL) 35

FI SYSTEM TROUBLESHOOTING

CUSTOMER COMPLAINT ANALYSIS

Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name:

Date of issue:

Model:

Date Reg.

VIN:

Date of problem: Mileage:

Malfunction indicator lamp condition (LED)

Malfunction display/code

(LCD)

Always ON Sometimes ON Always OFF Good condition

User mode:

Dealer mode:

No display

No code

Malfunction display ( )

Malfunction code ( )

PROBLEM SYMPTOMS

Poor Driveability Difficult Starting

No initial combustion

No combustion

Poor starting at

( cold warm always)

Other

Poor Idling

Poor fast Idle

Abnormal idling speed

( High Low) ( r/min)

Unstable

Hesitation on acceleration

Back fire/ After fire

Surging

Abnormal knocking

Engine rpm jumps briefly

Other

Engine Stall when

Immediately after start

Throttle valve is opened

Throttle valve is closed

Load is applied

Other Hunting ( r/min. to r/min)

Other

OTHERS:

36 VL800K5 (’05-MODEL)

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition

Weather

Temperature

Frequency

Fair Cloudy Rain Snow Always Other

Hot Warm Cool Cold ( °F/ °C) Always

Always Sometimes ( times/ day, month) Only once

Under certain condition

Urban Suburb Highway Mountainous ( Uphill Downhill) Road

Tarmacadam Gravel Other

Motorcycle condition

Engine condition

Cold Warming up phase Warmed up Always Other at starting

Immediately after start Racing without load Engine speed ( r/min)

Motorcycle condition

During driving: Constant speed Accelerating Decelerating

Right hand corner Left hand corner At stop

Motorcycle speed when problem occurs ( km/h, Mile/h)

Other

NOTE:

The above form is a standard sample. The form should be modified according to condition and characteristics of each market.

VISUAL INSPECTION

• Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.

* Engine oil level and leakage. (

$VL800K1 2-8)

* Engine coolant level and leakage. (

$VL800K1 2-13)

* Fuel level and leakage. (

* Clogged air cleaner element. (

* Battery condition. (

$VL800K1 8-31)

* Throttle cable play. (

$VL800K1 2-11)

* Vacuum hoses looseness, bend and disconnection.

* Broken fuse.

* Each warning light operation. (

$VL800K1 8-21)

* Exhaust gas leakage and noise. (

$VL800K1 2-19)

* Each coupler disconnection.

* Clogged radiator core. (

$VL800K1 6-5)

SELF-DIAGNOSTIC PROCEDURES

NOTE:

* Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in the memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the special tool.

* Before checking malfunction code, read SELF-DIAGNOSIS

FUNCTION “USER MODE and DEALER MODE” (

30 and 31) carefully to have good understanding as to what functions are available and how to use it.

* Be sure to read “PRECAUTIONS for Electrical Circuit Service”

(

Page 18) before inspection and observe what is written there.

• Remove the right frame cover. (

$VL800K1 7-2)

• Connect the special tool to the dealer mode coupler

A at the more than 4 seconds.

wiring harness, and start the engine or crank the engine for

• Turn the special tool’s switch ON and check the malfunction

code to determine the malfunction part.

" 09930-82720: Mode select switch

VL800K5 (’05-MODEL) 37

38 VL800K5 (’05-MODEL)

SELF-DIAGNOSIS RESET PROCEDURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• If the malfunction code indicates (C00), the malfunction is cleared.

• Disconnect the special tool from the dealer mode coupler.

NOTE:

* Even though the malfunction code (C00) is indicated, the previous malfunction history code still remains stored in the ECM.

Therefore, erase the history code memorized in the ECM using

SDS.

* The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

USE OF SDS DIAGNOSTIC PROCEDURES

NOTE:

* Don’t disconnect couplers from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ECM memory.

* Malfunction code stored in ECM memory can be checked by the SDS.

* Be sure to read “PRECAUTIONS for Electrical Circuit Service”

(

Page 18) before inspection and observe what is written there.

• Remove the right frame cover. (

$VL800K1 7-2)

• Set up the SDS tool. (Refer to the SDS operation manual for

further details)

• Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaing data at the time of DTC) according to instructions displayed on SDS.

• Not only is SDS used for detecting Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger.

• How to use trigger. (Refer to the SDS operation manual for further details)

" 09904-41010: SDS Set

99565-01010-004: CD-ROM Ver.4

USE OF SDS DIAGNOSIS RESET PROCE-

DURE

• After repairing the trouble, turn OFF the ignition switch and turn ON again.

• Click the DTC inspection button

• Check the DTC.

• The previous malfunction history code (Past DTC) still remains stored in the ECM. Therefore, erase the history code memorized in the ECM using SDS tool.

NOTE:

The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefore, when a wire coupler has been disconnected at the time of diagnosis, erase the stored malfunction history code using SDS.

• Click “Clear”

2 to delete history code (Past DTC).

VL800K5 (’05-MODEL) 39

• Check that both “Current DTC”

3 and “Past DTC” 4 are deleted (NIL).

40 VL800K5 (’05-MODEL)

SHOW DATA WHEN TROUBLE

(DISPLAYING DATA AT THE TIME OF DTC)

ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”.

Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble. This show data when trouble function can record the maximum of two Diagnostic Trouble

Codes in the ECM.

Also, ECM has a function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. lts use is helpful when rechecking or diagnosing a trouble.

• Click “Show data when trouble”

1 to display the data. By clicking the drop down button

2, either “Failure #1” or “Failure

#2” can be selected.

VL800K5 (’05-MODEL) 41

42 VL800K5 (’05-MODEL)

ECM TERMINAL

TERMINAL

NO.

CIRCUIT

GP switch signal (GP)

TERMINAL

NO.

CIRCUIT

Ignition switch signal (AT)

IAT sensor signal (IAT)

Rear cylinder IAP sensor signal (IAP. R) TO sensor signal (TOS)

STP sensor signal (STP) TP sensor signal (TP)

Blank

Front cylinder IAP sensor signal (IAP. F)

Power source for sensors (VCC)

HO2 sensor signal (HO2S)

[For E-02, 19, 24]

Clutch lever position switch (CLP)

CKP sensor signal (CKP-)

Power source for fuel injector (VM)

Power source (B+1)

ECM ground (E1)

Sensors ground (E2)

Blank

HO2 control selector (EXS)

[For E-02, 19, 24]

Starter switch (STA)

Neutral switch (NT)

CKP sensor signal (CKP+)

–

Blank

Serial data for speedometer (TECH)

–

ECT sensor signal (ECT)

Serial data for self-diagnosis (SDL)

–

TERMINAL

NO.

[

]

^ a b c

CIRCUIT

STVA signal (STVA. 1B)

HO2 sensor heater (HO2. H)

[For E-02, 19, 24]

STVA signal (STVA. 1A)

Blank

Ground (E01)

Rear cylinder Fuel injector (#1)

Rear cylinder Fuel injector (#2)

Blank

Front cylinder Ignition coil (IG2)

TERMINAL

NO.

CIRCUIT

STVA signal (STVA. 2B)

Fuel pump relay (FP Relay) e f g h i j k l

STVA signal (STVA. 2A)

PAIR control solenoid valve (PAIR)

Ground (E02)

Blank

Rear cylinder Ignition coil (IG1)

VL800K5 (’05-MODEL) 43

MALFUNCTION CODE AND DEFECTIVE CONDITION

DTC No.

C00

C12

P0335

C13/C17

P1750/P0105

C14

P0120

C15

P0115

CHECK FOR

DETECTED

ITEM

DETECTED FAILURE CONDITION

NO FAULT –––––––––––

CKP sensor The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

–––––––––––

CKP sensor wiring and mechanical parts.

(CKP sensor, lead wire/coupler connection)

IAP sensor, lead wire/coupler connection.

IAP sensor The sensor should produce following voltage.

TP sensor

0.1 V sensor voltage < 4.8 V

In other than the above range, C13

(P1750) or C17 (P0105) is indicated.

The sensor should produce following voltage.

TP sensor, lead wire/coupler connection.

0.1 V sensor voltage < 4.8 V

In other than the above range, C14

(P0120) is indicated.

value.

Sensor voltage is higher than specified

TP sensor circuit shorted to

VCC or ground circuit open.

value.

TP sensor circuit open or shorted to ground or VCC circuit open.

ECT sensor The sensor voltage should be the following.

0.1 V sensor voltage < 4.6 V

In other than the above range, C15

Sensor voltage is higher than specified value.

ECT sensor, lead wire/coupler connection.

ECT sensor circuit open or ground circuit open.

Sensor voltage is lower than specified value.

ECT sensor circuit shorted to ground.

44 VL800K5 (’05-MODEL)

DTC No.

C21

P0110

C23

P1651

C24/C25

P0351/P0352

C28

P1655

C29

P1654

DETECTED

ITEM

DETECTED FAILURE CONDITION

IAT sensor The sensor voltage should be the following.

TO sensor

0.1 V sensor voltage < 4.6 V

In other than the above range, C21

(P0110) is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.

CHECK FOR

IAT sensor, lead wire/coupler connection.

IAT sensor circuit open or ground circuit open.

IAT sensor circuit shorted to ground.

TO sensor, lead wire/coupler connection.

0.2 V sensor voltage 4.6 V

In other than the above value, C23

(P1651) is indicated.

Sensor voltage is higher than specified TO sensor circuit open or

Ignition signal value.

Sensor voltage is lower than specified shorted to VCC or ground circuit open.

value.

CKP sensor (pick-up coil) signal is produced, but signal from ignition coil is

ground or VCC circuit open.

Ignition coil, lead wire/coupler connection, power supply from the battery.

Secondary throttle valve ously. In this case, the code C24

(P0351) or C25 (P0352) is indicated.

actuator supplied from the ECM, communication signal does not reach ECM or

STVA moter, STVA lead wire/coupler.

operation voltage does not reach

STVA motor, C28 (P1655) is indicated.

STVA can not operate.

STP sensor The sensor should produce following voltage.

STP sensor, lead wire/coupler connection.

0.1 V sensor voltage < 4.8 V

In other than the above range, C29 is indicated.

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

STP sensor circuit shorted to

VCC or ground circuit open.

STP sensor circuit open or shorted to ground or VCC circuit open.

VL800K5 (’05-MODEL) 45

DTC No.

C31

P0705

C32/C33

P0201/P0202

C41

P0230

C42

P1650

C44

P0130

C44

P0135

C49

P1656

DETECTED

ITEM

Gear position signal

DETECTED FAILURE CONDITION

Gear position signal voltage should be higher than the following for 3 seconds and more.

Gear position sensor voltage > 0.6 V

If lower than the above value, C31

(P0705) is indicated.

Fuel injector CKP sensor (pickup coil) signal is produced, but fuel injector signal is inter-

Fuel pump relay rupted 4 times or more continuously. In this case, the code C32 (P0201) or

C33 (P0202) is indicated.

No voltage is applied to the fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump, although fuel pump relay is turned

OFF.

CHECK FOR

GP switch, lead wire/coupler connection. Gearshift cam etc.

Fuel injector, wiring/coupler connection, power supply to the injector.

Fuel pump relay, lead wire/coupler connection. power source to the fuel pump relay and fuel injectors.

Ignition switch

HO2 sensor

(E-02, 19, 24)

Ignition switch signal is not input to

ECM.

Ignition switch, lead wire/coupler.

HO2 sensor circuit open or shorted to ground.

running condition.

(Sensor voltage 0.1 V)

(P0130) is indicated.

The Heater can not operate so that

(P0135) is indicated.

HO2 sensor lead wire/coupler connection.

Battery voltage supply to the

HO2 sensor.

PAIR control PAIR control solenoid valve voltage is PAIR control solenoid valve, lead not input to ECM.

wire/coupler.

solenoid valve

46 VL800K5 (’05-MODEL)

“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION

The signal does not reach ECM for 3 sec. or more, after receiving the starter signal.

POSSIBLE CAUSE

• Metal particles or foreign material being stuck on the CKP sensor and rotor tip.

• CKP sensor circuit open or short.

• CKP sensor malfunction.

• ECM malfunction.

CKP sensor

G/Y

ECM

CKP+

CKP-

To Regulator/Rectifier

GEN

INSPECTION

Step 1

1) Remove the left frame cover. (

$VL800K1 7-2)

2) Remove the left frame lower cover

1 and tool box cover 2.

3) Remove the tool box

4) Check the CKP sensor coupler

4 for loose or poor contacts.

If OK, then measure the CKP sensor resistance.

5) Disconnect the CKP sensor coupler and measure the resistance.

! CKP sensor resistance: 184 – 276 Ω

(Blue – Green)

6) Also, check the continuity between each terminal and ground.

! CKP sensor continuity: ∞ Ω (Infinity)

(Blue – Ground)

(Green – Ground)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Are the resistance and continuity OK?

YES

Go to step 2.

Replace the CKP sensor with a new one.

7) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 47

48 VL800K5 (’05-MODEL)

Step 2

1) Disconnect the CKP sensor coupler.

2) Crank the engine a few seconds with the starter motor, and measure the CKP sensor peak voltage at the coupler.

! CKP sensor peak voltage: 4.0 V and more

(

+ Green – - Blue)

1 Peak volt adaptor

3) Repeat the above test procedure a few times and measure the highest peak voltage.

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

• Brown or G/Y wire open or shorted to ground, or poor

9 or Q connection.

• If wire and connection are OK, intermittent trou-

NO ble or faulty ECM.

YES

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

pler or ECM coupler.

• Loose or poor contacts on the CKP sensor cou-

(

$Page 39)

4) After repairing the trouble, clear the DTC using SDS tool.

Wire harness side

VL800K5 (’05-MODEL) 49

“C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION

DETECTED CONDITION

C13/C17 IAP sensor voltage is not within the following range.

0.1 V Sensor voltage < 4.8 V

NOTE:

Note that atmospheric pressure varies depending on weather conditions as well as altitude.

Take that into consideration when inspecting voltage.

POSSIBLE CAUSE

• Clogged vacuum passage between throttle body and IAP sensor.

• Air being drawn from vacuum passage between throttle body and IAP sensor.

• IAP sensor circuit open or shorted to ground.

• IAP sensor malfunction.

• ECM malfunction.

IAP sensor #2 (Front cylinder)

G/B

B/Br

IAP sensor #1 (Rear cylinder)

INSPECTION

G/W

B/Br

Step 1

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the IAP sensor couplers (Front cylinder side

1 or rear cylinder side

ECM

VCC

IAP (F)

IAP (R)

4) Disconnect the IAP sensor couplers.

5) Turn the ignition switch ON.

6) Measure the voltage at the Red wire

3 and ground.

7) Also, measure the voltage at the Red wire

3 and B/Br wire

! IAP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the Red wire or B/Br wire.

50 VL800K5 (’05-MODEL)

Step 2

1) Connect the IAP sensor couplers and install the fuel tank.

2) Insert the needle pointed probes to the lead wire coupler.

Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between G/B and

B/Br wires or between G/W and B/Br wires).

! IAP sensor output voltage: Approx. 2.6 V at idle speed

(Front cylinder:

+ G/B – - B/Br)

(Rear cylinder:

+ G/W – - B/Br)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

YES

Go to Step 3.

• Check the vacuum hose for crack or damage.

• Open or short circuit in the G/B or G/W wire.

• Replace the IAP sensor with a new one.

3) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Step 3

1) Remove the IAP sensor.

2) Connect the vacuum pump gauge to the vacuum port of the

IAP sensor.

Arrange 3 new 1.5 V batteries in series voltage is 4.5 – 5.5 V) and connect

- terminal to the ground terminal

2 and + terminal to the Vcc terminal 3.

3) Check the voltage between Vout

4 and ground. Also, check

" 09917-47011: Vacuum pump gauge

1 (check that total -

by using vacuum pump gauge. (

$Page 50)

09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

VL800K5 (’05-MODEL) 51

Is the voltage OK?

YES

• G/B, G/W, R or B/Br wire open or shorted to ground, or poor

L, 3, 6 or D connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

If check result is not satisfactory, replace IAP sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Output voltage (Vcc voltage 4.5 – 5.5 V, ambient temp. 20 –

30 °C, 68 – 86 °F)

ALTITUDE

(Reference)

(ft)



2 000

2 001



5 000

(m)



610

611



1 524

5 001



8 000

8 001



10 000

1 524



2 438

2 439



3 048

ATMOSPHERIC OUTPUT

PRESSURE VOLTAGE

(mmHg)

760



707



634

567



 kPa

100



(V)

3.4 – 4.0



2.6 – 3.4

2.4 – 3.1

526 70

Wire harness side

52 VL800K5 (’05-MODEL)

“C14” (P0120) TP SENSOR CIRCUIT MALFUNCTION

C14

P0120

DETECTED CONDITION

Output voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.1 V Sensor voltage < 4.8 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• TP sensor maladjusted.

• TP sensor circuit open or short.

• TP sensor malfunction.

• ECM malfunction.

• TP sensor circuit shorted to VCC or ground circuit open.

• TP sensor circuit open or shorted to ground or

VCC circuit open.

TP sensor

B B/Br

Bl R

INSPECTION

Step 1 (When indicating C14:)

1) Remove the fuel tank. (

$Page 93)

Bl/B

2) Turn the ignition switch OFF.

3) Check the TP sensor coupler for loose or poor contacts.

4) Disconnect the TP sensor coupler.

VCC

ECM

5) Turn the ignition switch ON.

6) Measure the voltage at the Red wire and ground.

7) Also, measure the voltage at the Red wire and B/Br wire.

! TP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the Red wire or B/Br wire.

VL800K5 (’05-MODEL) 53

Step 1 (When indicating P0120-H:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the TP sensor coupler for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

4) Disconnect the TP sensor coupler.

5) Check the continuity between Bl/B wire

A and Red wire B. If sound is not heard from the tester, the circuit condition is OK.

6) Disconnect the ECM coupler.

7) Check the continuity between Bl/B wire

A and terminal K.

8) Also, check the continuity between B/Br wire

C and terminal

! TPS lead wire continuity: Continuity (()

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

YES Go to Step 2.

NO Bl/B wire shorted to VCC or B/Br wire open.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

54 VL800K5 (’05-MODEL)

Step 1 (When indicating P0120-L:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the TP sensor coupler for loose or poor contacts.

If OK, then check the TP sensor lead wire continuity.

4) Disconnect the TP sensor coupler.

5) Check the continuity between Bl/B wire

A and ground.

6) Also, check the continuity between Bl/B wire

A and B/Br wire

B. If sound is not heard from the tester, the circuit condition is OK.

7) Disconnect the ECM coupler.

8) Check the continuity between Red wire

9) Also, check the continuity between Bl/B wire

A and terminal

" 09900-25008: Multi-circuit tester set

B and terminal 6.

! TPS lead wire continuity: Continuity (()

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

Go to Step 1 (

$Page 52) and Go to Step 2.

YES

Red or Bl/B wire open, or Bl/B wire shorted to ground.

10) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

Step 2

1) Turn the ignition switch OFF.

2) Disconnect the TP sensor coupler.

3) Check the continuity between Yellow wire and ground.

! TP sensor continuity: ∞ Ω (Infinity)

(Yellow – Ground)

4) If OK, then measure the TP sensor resistance at the terminals (between Yellow wire and Black wire).

5) Turn the throttle grip and measure the resistance.

! TP sensor resistance

Throttle valve is closed : Approx. 1.1 k

Ω

Throttle valve is opened: Approx. 4.3 k

Ω

6) Also, measure the TP sensor resistance at the test harness terminals (between Blue wire and Black wire).

! TP sensor resistance: Approx. 4.66 kΩ

(Blue wire – Black wire)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Are the continuity and resistance OK?

YES Go to Step 3.

• Reset the TP sensor position correctly.

• Replace the TP sensor with a new one.

7) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 55

56 VL800K5 (’05-MODEL)

Step 3

1) Connect the TP sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Turn the ignition switch ON.

4) Measure the TP sensor output voltage at the coupler

(between

+ Bl/B wire and - B/Br wire) by turning the throttle grip.

! TP sensor output voltage

Throttle valve is closed : Approx. 1.1 V

Throttle valve is opened: Approx. 4.3 V

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

• R, B/Br or Bl/B wire open or shorted to ground, or poor

6, D or K connection.

• If wire and connection are OK, intermittent trou-

YES

NO ble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

sor with a new one.

5) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

VL800K5 (’05-MODEL) 57

“C15” (P0115) ECT SENSOR CIRCUIT MALFUNCTION

C15

P0115

DETECTED CONDITION

Output voltage is not within the following range.

0.1 Sensor voltage < 4.6 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• ECT sensor circuit open or short.

• ECT sensor malfunction.

• ECM malfunction.

• ECT sensor circuit open or ground circuit open.

• ECT sensor circuit shorted to ground.

ECT sensor

B/Bl

B/Br

INSPECTION

Step 1 (When indicating C15:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

coupler.

4) Disconnect the coupler and turn the ignition switch ON.

5) Measure the voltage between B/Bl wire terminal

1 and ground.

6) Also, measure the voltage between B/Bl wire terminal

1 and

B/Br wire terminal

! ECT sensor voltage: 4.5 – 5.5 V

(

+ B/Bl – - Ground)

(

+ B/Bl – - B/Br)

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the B/Bl wire or B/Br wire.

ECM

ECT

58 VL800K5 (’05-MODEL)

Step 1 (When indicating P0115-H:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the ECT sensor coupler for loose or poor contacts.

If OK, then check the ECT sensor lead wire continuity.

4) Disconnect the ECT sensor coupler and ECM coupler.

5) Check the continuity between B/Bl wire

A and terminal I.

6) Also, check the continuity between B/Br wire

B and terminal

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

YES

Go to Step 2.

B/Bl or B/Br wire open.

7) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

Step 1 (When indicating P0115-L:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the ECT sensor coupler for loose or poor contacts.

If OK, then check the ECT sensor lead wire continuity.

4) Disconnect the ECT sensor coupler.

5) Check the continuity between B/Bl wire

1 and ground. If sound is not heard from the tester, the circuit condition is OK.

) Tester knob indication: Continuity test (()

6) Connect the ECT sensor coupler.

7) Turn the ignition switch ON.

8) Measure the voltage between B/Bl wire and ground.

! Output voltage: 0.1 – 4.6 V (

+ B/Bl – - Ground)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

YES Go to Step 1 (

$Page 57) and Go to Step 2.

NO B/Bl wire shorted to ground.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 59

60 VL800K5 (’05-MODEL)

Step 2

1) Turn the ignition switch OFF.

2) Measure the ECT sensor resistance.

! ECT sensor resistance:

Approx. 2.3 – 2.6 k

Ω at 20 °C (68 °F)

(Terminal – Terminal)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

3) Remove the ECT sensor.

4) Check the ECT sensor by testing it at the bench as shown in the figure. Connect the ECT sensor

1 to a circuit tester and place it in the oil

2 contained in a pan, which is placed on a stove.

5) Heat the oil to raise its temperature slowly and read the column thermometer

3 and the ohmmeter.

! Temperature sensor specification

Engine Coolant Temp

20 °C (68 °F)

40 °C (104 °F)

60 °C (140 °F)

80 °C (176 °F)

Resistance

Approx. 2.45 k

Ω

Approx. 1.148 k

Ω

Approx. 0.587 k

Ω

Approx. 0.322 k

Ω

* Take special care when handling the ECT sensor. It

* Do not contact the ECT sensor and the column thermometer with a pan.

Is the resistance OK?

YES

• B/Br or B/Bl wire open or shorted to ground, or poor

D or I connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

Replace the ECT sensor with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

VL800K5 (’05-MODEL) 61

“C21” (P0110) IAT SENSOR CIRCUIT MALFUNCTION

C21

P0110

DETECTED CONDITION

Output voltage is not within the following range.

0.1 Sensor voltage < 4.6 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• IAT sensor circuit open or short.

• IAT sensor malfunction.

• ECM malfunction.

• IAT sensor circuit open or ground circuit open.

• IAT sensor circuit shorted to ground.

IAT sensor

B/Br

INSPECTION

Step 1 (When indicating C21:)

1) Remove the air cleaner box. (

$Page 103)

2) Turn the ignition switch OFF.

coupler.

4) Disconnect the coupler and turn the ignition switch ON.

5) Measure the voltage between Dg wire terminal and ground.

6) Also, measure the voltage between Dg wire terminal and B/Br wire terminal.

! IAT sensor voltage: 4.5 – 5.5 V

(

+ Dg – - Ground)

(

+ Dg – - B/Br)

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the Dg wire or B/Br wire.

ECM

IAT

62 VL800K5 (’05-MODEL)

Step 1 (When indicating P0110-H:)

1) Remove the air cleaner box. (

$Page 103)

2) Turn the ignition switch OFF.

3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

4) Disconnect the IAT sensor coupler and ECM coupler.

5) Check the continuity between Dg wire

A and terminal 2.

6) Also, check the continuity between B/Br wire

B and terminal

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

YES

Go to Step 2.

Dg or B/Br wire open.

7) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

Step 1 (When indicating P0110-L:)

1) Remove the air cleaner box. (

$Page 103)

2) Turn the ignition switch OFF.

3) Check the IAT sensor coupler for loose or poor contacts.

If OK, then check the IAT sensor lead wire continuity.

4) Disconnect the IAT sensor coupler.

5) Check the continuity between Dg wire and ground. If sound is not heard from the tester, the circuit condition is OK.

) Tester knob indication: Continuity test (()

6) Connect the IAT sensor coupler.

7) Turn the ignition switch ON.

8) Measure the voltage between Dg wire and ground.

! Output voltage: 0.1 – 4.6 V (

+ Dg –

" 09900-25008: Multi-circuit tester set

- Ground)

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

YES Go to Step 1 (

$Page 61) and Go to Step 2.

NO Dg wire shorted to ground.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 63

64 VL800K5 (’05-MODEL)

Step 2

1) Turn the ignition switch OFF.

2) Measure the IAT sensor resistance.

! IAT sensor resistance:

Approx. 2.6 k

Ω at 20 °C (68 °F) (Terminal – Terminal)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES

• Dg or B/Br wire open or shorted to ground, or poor

2 or D connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and

NO inspect it again.

Replace the IAT sensor with a new one.

Intake Air Temp

20 °C (68 °F)

50 °C (122 °F)

Resistance

Approx. 2.6 k

Ω

Approx. 0.8 k

Ω

Approx. 0.3 k

Ω

80 °C (176 °F)

110 °C (230 °F)

NOTE:

Approx. 0.2 k

Ω

IAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to Page 60 for details.

Wire harness side

3) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 65

“C23” (P1651) TO SENSOR CIRCUIT MALFUNCTION

C23

P1651

DETECTED CONDITION

The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.

0.2 Sensor voltage < 4.6 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• TO sensor circuit open or short.

• TO sensor malfunction.

• ECM malfunction.

• TO sensor ground circuit open or shorted to VCC.

• TO sensor circuit open or shorted to ground or

VCC circuit open.

TO sensor

Br/W

B/Br

ECM

VCC

INSPECTION

Step 1 (When indicating C23:)

1) Remove the right frame cover. (

$VL800K1 7-2)

2) Turn the ignition switch OFF.

If OK, then measure the TO sensor resistance.

4) Disconnect the TO sensor coupler.

5) Measure the resistance between terminal

A and terminal B.

! TO sensor resistance: 19.1 – 19.7 kΩ

(Terminal

A – Terminal B)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES

Go to Step 2.

Replace the TO sensor with a new one.

66 VL800K5 (’05-MODEL)

Step 1 (When indicating P1651-H:)

1) Remove the right frame cover. (

$VL800K1 7-2)

2) Turn the ignition switch OFF.

3) Check the TO sensor coupler for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

4) Disconnect the TO sensor coupler.

5) Check the continuity between Br/W wire

A and Red wire B.

If sound is not heard from the tester, the circuit condition is

OK.

6) Disconnect the ECM coupler.

7) Also, Check the continuity between Br/W wire

A and terminal

8) Also, check the continuity between B/Br wire

C and terminal

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

Br/W wire shorted to VCC, or B/Br wire open.

YES

Go to Step 2.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

VL800K5 (’05-MODEL) 67

Step 1 (When indicating P1651-L:)

1) Remove the right frame cover. (

$VL800K1 7-2)

2) Turn the ignition switch OFF.

3) Check the TO sensor coupler for loose or poor contacts.

If OK, then check the TO sensor lead wire continuity.

4) Disconnect the TO sensor coupler.

5) Check the continuity between Br/W wire

A and ground.

6) Also, check the continuity between Br/W wire

A and B/Br wire

B. If sound is not heard from the tester, the circuit condition is OK.

7) Disconnect the ECM coupler.

8) Also, check the continuity between Red wire

C and terminal

9) Also, check the continuity between Br/W wire

A and terminal

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

Red or Br/W wire open, or Br/W wire shorted to

YES

Go to Step 2.

ground.

10) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

68 VL800K5 (’05-MODEL)

Step 2

1) Connect the TO sensor coupler.

2) Insert the needle pointed probes to the lead wire coupler.

3) Turn the ignition switch ON.

4) Measure the voltage at the wire side coupler between Br/W and B/Br wires.

! TO sensor voltage: 0.4 – 1.4 V

(

+ Br/W – - B/Br)

Also, measure the voltage when leaning the motorcycle.

5) Dismount the TO sensor from its bracket and measure the voltage when it is leaned 65 ° and more, left and right, from the horizontal level.

! TO sensor voltage: 3.7 – 4.4 V

(

+ Br/W – - B/Br)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

• Red, B/Br or Br/W wire open or shorted to ground, or poor

6, D or J connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

inspect it again.

• Loose or poor contacts on the ECM coupler.

65 ˚

Wire harness side

NO • Open or short circuit.

• Replace the TO sensor with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

“C24” (P0351) or “C25” (P0352) IGNITION SYSTEM MALFUNCTION

*Refer to the IGNITION SYSTEM for details. (

$VL800K1 8-18)

VL800K5 (’05-MODEL) 69

“C28” (P1655) STV ACTUATOR CIRCUIT MALFUNCTION

DETECTED CONDITION

The operation voltage does not reach the STVA.

ECM does not receive communication signal from the STVA.

POSSIBLE CAUSE

• STVA malfunction.

• STVA circuit open or short.

• STVA motor malfunction.

STV ACTUATOR

W/B

B/Lg

P/W

ECM

STVA. 1B

STVA. 1A

STVA. 2B

STVA. 2A

INSPECTION

Step 1

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the STVA lead wire coupler for loose or poor contacts.

4) Remove the air intake pipe. (

5) Turn the ignition switch ON to check the STVA operation.

(STV operating order: 95% open

→ Full open → 95% open)

Is the operation OK?

YES

Go to Step 2.

• Loose or poor contacts on the STVA coupler.

• Open or short circuit in the (P/W or Black) and

(B/Lg or Green) wires.

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

70 VL800K5 (’05-MODEL)

Step 2

1) Turn the ignition switch OFF.

2) Disconnect the STVA lead wire coupler.

3) Check the continuity between each wire terminal and ground.

! STVA continuity: ∞ Ω (Infinity)

4) If OK, then measure the STVA resistance. (between Black wire terminal and Pink wire terminal) and (between Green wire terminal and W/B wire terminal)

! STVA resistance: Approx. 6.5 Ω

(Black – Pink)

(Green – W/B)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES

• B/Lg, P/W, Green and Black wire open or shorted to ground, or poor

Y , [ , d and f connection.

ble or faulty ECM.

• Recheck each terminal and wire harness for

inspect it again.

• Loose or poor contacts on the ECM coupler.

Wire harness side

• Replace the STVA with a new one.

5) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for further details)

2) Turn the ignition switch ON.

3) Click “Secondary throttle operating control”

4) Click each button

At this time, if an operation sound is heard from STVA, the function is normal.

VL800K5 (’05-MODEL) 71

72 VL800K5 (’05-MODEL)

“C29” (P1654) STP SENSOR CIRCUIT MALFUNCTION

C29

P1654

DETECTED CONDITION

Signal voltage is not within the following range.

Difference between actual throttle opening and opening calculated by ECM is larger than specified value.

0.1 V Sensor voltage < 4.8 V

Sensor voltage is higher than specified value.

Sensor voltage is lower than specified value.

POSSIBLE CAUSE

• STP sensor maladjusted.

• STP sensor circuit open or short.

• STP sensor malfunction.

• ECM malfunction.

• STP sensor circuit shorted to VCC or ground circuit open.

• STP sensor circuit open or shorted to ground or

VCC circuit open.

STP sensor

B/Br

Step 1 (When indicating C29:)

1) Remove the fuel tank. (

$Page 93)

INSPECTION

Y/W

STP

2) Turn the ignition switch OFF.

3) Check the STP sensor coupler for loose or poor contacts.

VCC

ECM

4) Disconnect the STP sensor coupler.

5) Turn the ignition switch ON.

6) Measure the voltage at the Red wire and ground.

7) Also, measure the voltage at the Red wire and B/Br wire.

! STP sensor input voltage: 4.5 – 5.5 V

(

+ Red – - Ground)

(

+ Red – - B/Br)

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Open or short circuit in the Red wire or B/Br wire.

Step 1 (When indicating P1654-H:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the STP sensor coupler for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

4) Disconnect the STP sensor coupler.

5) Check the continuity between Y/W wire

A and Red wire B. If sound of the continuity is not heard from the tester, the circuit condition is OK.

6) Disconnect the ECM coupler.

7) Check the continuity between Y/W wire

A and terminal 4.

8) Also, check the continuity between B/Br wire

C and terminal

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

YES Go to Step 2.

Y/W wire shorted to VCC or B/Br wire open.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 73

Terminal side

74 VL800K5 (’05-MODEL)

Step 1 (When indicating P1654-L:)

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the STP sensor coupler for loose or poor contacts.

If OK, then check the STP sensor lead wire continuity.

4) Disconnect the STP sensor coupler.

5) Check the continuity between Y/W wire

A and ground.

6) Also, check the continuity between Y/W wire

A and B/Br wire

B. If sound is not heard from the tester, the circuit condition is OK.

7) Disconnect the ECM coupler.

8) Check the continuity between Red wire

C and terminal 6.

9) Also, check the continuity between Y/W wire

A and terminal

4. If sound of the continuity is not heard from the tester, the circuit condition is OK.

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

Go to Step 1 (

$Page 72) and Go to Step 2.

Red or Y/W wire open, or Y/W wire shorted to

YES

NO ground.

10) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

Step 2

1) Turn the ignition switch OFF.

2) Disconnect the STP sensor coupler.

3) Check the continuity between Yellow wire terminal and ground.

! STP sensor continuity: ∞ Ω (Infinity)

(Yellow – Ground)

6) If OK, then measure the STP sensor resistance at the coupler

(between Yellow and Black wires).

7) Close and open the secondary throttle valve fully by moving the fast idle link, and measure the valve closing and opening resistance.

! STP sensor resistance

Secondary throttle valve is closed

A : Approx. 0.5 k

Ω

Secondary throttle valve is opened

B: Approx. 3.9 k

Ω

8) If OK, then measure the STP sensor resistance at the wire

2 terminals (between Blue wire and Black wire).

! STP sensor resistance: Approx 4.69 kΩ

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Are the continuity and resistance OK?

YES

Go to Step 3.

• Reset the STP sensor position correctly.

• Replace the STP sensor with a new one.

9) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 75

76 VL800K5 (’05-MODEL)

Step 3

1) Turn the ignition switch OFF.

2) Connect the STP sensor coupler.

3) Insert the needle pointed probes to the STP sensor coupler.

4) Disconnect the STVA lead wire coupler.

5) Turn the ignition switch ON.

6) Measure the STP sensor output voltage at the coupler

(between

+ Y/W and - B/Br wires) when the secondary throttle valve is full closed and opened by moving the fast idle link.

! STP sensor output voltage

Throttle valve is closed

A : Approx. 0.5 V

Throttle valve is opened

B: Approx. 3.9 V

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

VL800K5 (’05-MODEL) 77

Is the voltage OK?

YES

• Y/W, R or B/Br wire open or shorted to ground, or poor

4, 6 or D connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

If check result is not satisfactory, replace STP sensor with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

78 VL800K5 (’05-MODEL)

“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION

DETECTED CONDITION

No Gear Position switch voltage.

Switch voltage is not within the following range.

Switch voltage > 0.6 V

POSSIBLE CAUSE

• Gear Position switch circuit open or short.

• Gear Position switch malfunction.

• ECM malfunction.

ECM

To engine stop switch

Side-stand relay

B/W

GP SWITCH

5 1

Neutral indicator light

Side-stand switch

Ignition switch

INSPECTION

Step 1

1) Remove the left frame cover. (

$VL800K1 7-2)

2) Remove the secondary gear case cover

3) Turn the ignition switch OFF.

4) Check the GP switch coupler for loose or poor contacts.

If OK, then measure the GP switch voltage.

VL800K5 (’05-MODEL) 79

5) Support the motorcycle with a jack.

6) Fold the side-stand to up position.

7) Make sure the engine stop switch is in the “RUN” position.

8) Insert the needle pointed probes to the lead wire coupler.

9) Turn the ignition switch ON.

10) Measure the voltage at the wire side coupler between Pink wire and ground, when shifting the gearshift lever from 1st to

Top.

! GP switch voltage: 0.6 V and more

(Pink – Ground)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

• Pink wire open or shorted to ground, or poor

1 connection.

• If wire and connection are OK, intermittent trou-

YES

NO ble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

inspect it again.

• Replace the ECM with a known good one, and

• Replace the GP switch with a new one.

11) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

80 VL800K5 (’05-MODEL)

“C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION

DETECTED CONDITION

CKP signal is produced but fuel injector signal is interrupted 4 times or more continuously.

POSSIBLE CAUSE

• Injector circuit open or short.

• Injector malfunction.

• ECM malfunction.

ECM

Y/R

To GPS

Fuel pump relay

To engine stop switch

Gr/B

Gr/W

(Front cylinder) (Rear cylinder)

Fuel inlector

INSPECTION

Step 1

1) Remove the air intake pipe. (

$Page 103)

2) Turn the ignition switch OFF.

3) Check the injector coupler for loose or poor contacts.

If OK, then measure the injector resistance.

between terminals.

4) Disconnect the injector coupler and measure the resistance

(Terminal – Terminal)

5) If OK, then check the continuity between each terminal and ground.

! Injector continuity: ∞ Ω (Infinity)

(Terminal – Ground)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Are the resistance and continuity OK?

YES

Go to Step 2.

Replace the Injector with a new one. (

$Page

111)

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

VL800K5 (’05-MODEL) 81

Step 2

1) Turn the ignition switch ON.

2) Measure the injector voltage between Y/R wire and ground.

! Injector voltage: Battery voltage

(

+ Y/R – - Ground)

NOTE:

Injector voltage can be detected only for 3 seconds after ignition switch is turned ON.

" 09900-25008: Multi-circuit tester set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

• Gr/B or Gr/W wire open or shorted to ground, or poor

^ or a connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

Open circuit in the Y/R wire.

(

$Page 39)

3) After repairing the trouble, clear the DTC using SDS tool.

Wire harness side

82 VL800K5 (’05-MODEL)

“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION

DETECTED CONDITION

No voltage is applied to fuel pump, although fuel pump relay is turned ON, or voltage is applied to fuel pump, although fuel pump relay is turned OFF.

POSSIBLE CAUSE

• Fuel pump relay circuit open or short.

• Fuel pump relay malfunction.

• ECM malfunction.

ECM

Fuel pump

FP Relay

Y/R

Engine stop switch

To GP switch

Side-stand relay

Fuel pump relay

R/Bl

O/W

INSPECTION

1) Remove the secondary gear case cover

Step 1

2) Turn the ignition switch OFF.

3) Check the FP relay coupler for loose or poor contacts.

4) If OK, then check the insulation and continuity. Refer to Page

96 for details.

Is the FP relay OK?

YES

• Yellow wire open or shorted to ground, or poor e connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

Replace the FP relay with a new one.

5) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

Ignition switch

VL800K5 (’05-MODEL) 83

“C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION

DETECTED CONDITION

PAIR control solenoid valve voltage is not input to

ECM.

POSSIBLE CAUSE

• PAIR control solenoid valve circuit open or short.

• PAIR control solenoid valve malfunction.

• ECM malfunction.

ECM

PAIR

Br/B O/W

Engine stop switch

To GP switch

Side-stand relay

Ignition switch

B/R B

PAIR CONTROL

SOLENOID VALVE

INSPECTION

Step 1

1) Remove the fuel tank. (

$Page 93)

2) Turn the ignition switch OFF.

3) Check the PAIR control solenoid valve coupler for loose or poor contacts.

tance.

5) Measure the resistance between terminals.

! PAIR control solenoid valve resistance:

20 – 24

Ω at 20 – 30 °C (68 – 86 °F)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Is the resistance OK?

YES

Go to Step 2.

• Loose or poor contacts on the ECM coupler.

• Replace the PAIR control solenoid valve with a new one.

6) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

84 VL800K5 (’05-MODEL)

Step 2

1) Connect the PAIR control solenoid valve coupler.

2) Turn the ignition switch ON.

3) Insert the needle pointed probes to the PAIR control solenoid valve coupler.

4) Measure the voltage at the wire side coupler between Black wire and ground.

! PAIR control solenoid valve voltage: Battery voltage

(

+ Black – - Ground)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

• Br/B wire open or shorted to ground, or g connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

YES

NO open circuit and poor connection.

inspect it again.

Open or short circuit in the Br/B wire.

(

$Page 39)

• Recheck each terminal and wire harness for

• Replace the ECM with a known good one, and

Wire harness side

ACTIVE CONTROL INSPECTION

1) Set up the SDS tool. (Refer to the SDS operation manual for further details)

2) Turn the ignition switch ON.

3) Click “PAIR Sol operating control”

4) Click each button

At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal.

VL800K5 (’05-MODEL) 85

86 VL800K5 (’05-MODEL)

“C44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION

(E-02, 19, 24)

C44

(P0130)

C44

(P0135)

DETECTED CONDITION

HO2 sensor output voltage is not input to ECM during engine operation and running condition.

(Sensor voltage 0.1 V)

POSSIBLE CAUSE

• HO2 sensor circuit open or shorted to ground.

• HO2 sensor malfunction.

• ECM malfunction.

The heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit.

• Battery voltage supply to the HO2 sensor.

ECM

HO2S

HO2. H

B+1

B/Br

W/Bl

W/B

O/G

Engine stop switch

O/W

To GP switch

Side-stand relay

INSPECTION

Step 1 (When indicating C44/P0130:)

HO2 sensor

2) Turn the ignition switch OFF.

1) Remove the right frame cover. (VL800K1 7-2)

If OK, then check the HO2 sensor lead wire continuity.

Ignition switch

VL800K5 (’05-MODEL) 87

4) Disconnect the HO2 sensor coupler and ECM coupler.

5) Check the continuity between W/Bl wire

A and terminal 7.

6) Also, check the continuity between W/Bl wire

A and ground.

If sound of the continuity is not heard from the tester, the circuit condition is OK.

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

) Tester knob indication: Continuity test (()

Is the continuity OK?

YES

Go to Step 2 (When indicating C44/P0130:).

W/Bl wire shorted to ground or W/Bl wire open.

7) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Terminal side

Step 2 (When indicating C44/P0130:)

1) Warm up the engine enough.

2) Insert the needle pointed probes to the HO2 sensor coupler.

3) If OK, then disconnect the PAIR solenoid valve hose and close the air inlet with a prop plug, measure the HO2 sensor

! HO2 sensor output voltage at idle speed:

0.4 V and less (

+ W/Bl – - B/Br)

0.6 V and more (

+ W/Bl – - B/Br)

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

• W/Bl or B/Br wire open or shorted to ground, or poor

7 or D connection.

• If wire and connection are OK, intermittent trouble or faulty ECM.

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and inspect it again.

Replace the HO2 sensor with a new one.

4) After repairing the trouble, clear the DTC using SDS tool.

(

$Page 39)

Wire harness side

88 VL800K5 (’05-MODEL)

Step 1 (When indicating C44/P0135:)

1) Remove the right frame cover. (VL800K1 7-2)

2) Turn the ignition switch OFF.

3) Check the HO2 sensor coupler for loose or poor contacts.

4) Insert the needle pointed probes to the HO2 sensor coupler.

5) Turn the ignition switch ON and measure the heater voltage between W/B wire (ECM side) and ground.

6) If the tester voltage indicates the battery voltage for few seconds, it is good condition.

! Heater voltage: Battery voltage (W/B – Ground)

NOTE:

Battery voltage can be detected only during few seconds after ignition switch is turned ON.

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

Is the voltage OK?

YES

• Loose or poor contacts on the ECM coupler.

• Open circuit in the W/B wire.

VL800K5 (’05-MODEL) 89

Step 2 (When indicating C44/P0135:)

1) Turn the ignition switch OFF.

2) Disconnect the HO2 sensor coupler.

3) Check the resistance between the terminals (White – White) of the HO2 sensor.

! HO2 heater resistance: 6.5 – 8.9 Ω (at 23 °C/73.4 °F)

(White – White)

NOTE:

* Temperature of the sensor affects resistance value largely.

* Make sure that the sensor heater is at correct temperature.

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

Is the resistance OK?

• O/W or W/B wire open or shorted to ground, or poor

A or Z connection.

• If wire and connection are OK, intermittent trou-

YES

NO ble or faulty ECM.

inspect it again.

Replace the HO2 sensor with a new one.

(

$Page 39)

• Recheck each terminal and wire harness for open circuit and poor connection.

• Replace the ECM with a known good one, and

Wire harness side

90 VL800K5 (’05-MODEL)

SENSORS

CKP SENSOR INSPECTION

The crankshaft position sensor is installed in the generator cover. (

$Page 46)

CKP SENSOR REMOVAL AND INSTALLATION

• Remove the generator cover. (

$VL800K1 3-18)

• Install the generator cover in the reverse order of removal.

IAP SENSOR INSPECTION

The intake air pressure sensor is installed on the air intake pipe.

(

$Page 49)

IAP SENSOR REMOVAL AND INSTALLATION

• Remove the fuel tank. (

$Page 93)

• Remove the IAP sensor from the air intake pipe.

• Install the IAP sensor in the reverse order of removal.

TP SENSOR INSPECTION

No.2 (Front cylinder) throttle body. (

$Page 52)

The throttle position sensor is installed at the right side of the

• Remove the TP sensor. (

$Page 105)

• Install the TP sensor in the reverse order of removal.

TPS ADJUSTMENT

• Adjust the TP sensor. (

$Page 33)

ECT SENSOR INSPECTION

The engine coolant temperature sensor is installed at the cylinder head cover. (

$Page 57)

ECT SENSOR REMOVAL AND INSTALLATION

• Remove the fuel tank. (

$Page 93)

• Remove the ECT sensor.

• Install the ECT sensor in the reverse order of removal.

* ECT sensor: 18 N·m (1.8 kgf-m, 13.0 lb-ft)

IAT SENSOR INSPECTION

The intake air temperature sensor is installed at the back side of the air cleaner box. (

$Page 61)

IAT SENSOR REMOVAL AND INSTALLATION

• Remove the air cleaner box. (

$Page 103)

• Remove the IAT sensor from the air cleaner box.

• Install the IAT sensor in the reverse order of removal.

TO SENSOR INSPECTION

TO SENSOR REMOVAL AND INSTALLATION

The tip-over sensor is located in under the seat. (

$Page 65)

• Remove the right frame cover. (

$VL800K1 7-2)

• Remove the TO sensor from the frame.

• Install the TO sensor in the reverse order of removal.

NOTE:

When installing the TO sensor, the arrow mark must be pointed upward.

STP SENSOR INSPECTION

STP SENSOR REMOVAL AND INSTALLATION

The secondary throttle position sensor is installed at the right side of the No.2 (Front cylinder) throttle body (

$Page 72).

• Remove the STP sensor. (

$Page 106)

• Install the STP sensor in the reverse order of removal.

STP SENSOR ADJUSTMENT

• Adjust the STP sensor. (

HO2 SENSOR INSPECTION (E-02, 19, 24)

HO2 SENSOR REMOVAL AND INSTALLATION

The HO2 sensor is installed at the muffler.

• Remove the right frame cover. (

$VL800K1 7-2)

• Disconnect the HO2 sensor lead wire coupler and remove the

HO2 sensor.

• Install the HO2 sensor in the reverse order of removal.

* HO2 sensor: 48.4 N·m (4.84 kgf-m, 35.0 lb-ft)

VL800K5 (’05-MODEL) 91

92 VL800K5 (’05-MODEL)

FUEL DELIVERY SYSTEM

The fuel delivery system consists of the fuel tank, fuel pump, fuel filters, fuel feed hose, fuel delivery pipe

(including fuel injectors) and fuel pressure regulator. There is no fuel return hose. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe.

Fuel pressure is regulated by the fuel pressure regulator. As the fuel pressure applied to the fuel injector (the fuel pressure in the fuel delivery pipe) is always kept at absolute fuel pressure of 3.0 kgf/cm² (300 kPa, 43 psi), the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM.

The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

1 Fuel tank

2 Fuel filter (For high pressure)

3 Fuel pressure regulator

4 Fuel delivery pipe

5 Fuel injector

6 Fuel feed hose

7 Fuel mesh filter (For low pressure)

8 Fuel pump

A Before-pressurized fuel

B Pressurized fuel

C Relieved fuel

FUEL SYSTEM

FUEL TANK LIFT-UP

• Remove the seat. (

$VL800K1 7-2)

• Remove the fuel tank mounting bolt

• Lift and support the fuel tank about 10 cm (3.94 in) with the prop stay.

NOTE:

Be careful not to lift the fuel tank more than about 10 cm (3.94

in), or hoses will be twisted.

FUEL TANK REMOVAL

• Remove the speedometer. (

$VL800K1 5-3)

• Lift and support the fuel tank. (

$Page 93)

• Disconnect the fuel pump lead wire coupler

hose

• Place a rag under the fuel feed hose and remove the fuel feed

When removing the fuel tank, do not leave the fuel feed hose

2 on the fuel tank side.

Gasoline is highly flammable and explosive.

Keep heat, spark and flame away.

• Remove the fuel tank.

Be careful not to damage the frame

A by the fuel tank.

FUEL TANK INSTALLATION

• Installation is in the reverse order of removal.

VL800K5 (’05-MODEL) 93

94 VL800K5 (’05-MODEL)

FUEL PRESSURE INSPECTION

• Lift and support the fuel tank. (

$Page 93)

• Place a rag under the fuel feed hose.

• Remove the fuel feed hose

• Install the special tools between the fuel tank and fuel delivery pipe.

" 09940-40211: Fuel pressure gauge adaptor

09940-40220: Fuel pressure gauge hose attachment

09915-77331: Oil pressure gauge

09915-74521: Oil pressure gauge hose

Turn the ignition switch ON and check the fuel pressure.

! Fuel pressure: Approx. 300 kPa (3.0 kgf/cm², 43 psi)

If the fuel pressure is lower than the specification, inspect the following items:

* Fuel hose leakage

* Clogged fuel filter

* Pressure regulator

* Fuel pump

If the fuel pressure is higher than the specification, inspect the following items:

* Fuel pump check valve

* Pressure regulator

* Before removing the special tools, turn the ignition switch to OFF position and release the fuel pressure slowly.

* Gasoline is highly flammable and explosive. Keep heat, sparks and flame away.

A To fuel tank.

B To fuel delivery pipe.

FUEL PUMP INSPECTION

Turn the ignition switch ON and check that the fuel pump operates for few seconds.

If the fuel pump motor does not make operating sound, replace the fuel pump assembly or inspect the fuel pump relay and tip-over sensor.

FUEL DISCHARGE AMOUNT INSPECTION

Gasoline is highly flammable and explosive.

Keep heat, spark and flame away.

• Lift and support the fuel tank. (

$Page 93)

• Disconnect the fuel feed hose

1 from the fuel pump and fuel pump lead wire coupler

• Connect a proper fuel hose

3 to the fuel pump.

• Place the measuring cylinder and insert the fuel hose end into the measuring cylinder.

• Connect a proper lead wire into the fuel pump lead wire coupler (fuel pump side) and apply 12 volts to the fuel pump (Y/R wire) for 10 seconds and measure the amount of fuel discharged.

Battery

+ terminal

(Yellow with red tracer)

If the pump does not discharge the amount specified, it means that the fuel pump is defective or that the fuel filter is clogged.

! Fuel discharge amount: 168 ml and more/10 sec.

(5.7/5.9 US/Imp oz)/10 sec.

NOTE:

The battery must be in fully charged condition.

VL800K5 (’05-MODEL) 95

96 VL800K5 (’05-MODEL)

FUEL PUMP RELAY INSPECTION

Fuel pump relay is located inside the secondary gear case cover.

• Remove the secondary gear case cover.

• Remove the fuel pump relay

First, check the insulation between

A and B terminals with pocket tester. Then apply 12 volts to

C and D terminals, + to

C and - to D, and check the continuity between A and B.

If there is no continuity, replace it with a new one.

FUEL PUMP CONSTRUCTION

VL800K5 (’05-MODEL) 97

1 Fuel pump

2 Plate assy

3 Fuel mesh filter

4 Fuel mesh filter cover

5 Fuel feed hose

A Fuel pump mounting bolt

ITEM N·m kgf-m lb-ft

10 1.0

7.0

98 VL800K5 (’05-MODEL)

FUEL PUMP REMOVAL AND DISASSEMBLY

• Remove the fuel tank. (

$Page 93)

• Remove the fuel pump assembly

1 by removing its mounting bolts diagonally.

Gasoline is highly flammable and explosive.

Keep heat, spark and flame away.

• Remove the fuel mesh filter cover

• Disconnect the fuel pump coupler

• Remove the screw

4 and fuel pump holder

• Separate the fuel pump and delivery pipe

• Remove the fuel mesh filter

7 and rubber cushion 8.

VL800K5 (’05-MODEL) 99

FUEL MESH FILTER INSPECTION AND

CLEANING

If the fuel mesh filter is clogged with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

Blow the fuel mesh filter with compressed air.

NOTE:

If the fuel mesh filter is clogged with many sediment or rust,

100 VL800K5 (’05-MODEL)

FUEL PUMP REASSEMBLY AND INSTALLA-

TION

Install the fuel pump in the reverse order of removal and disassembly. Pay attention to the following points:

• Install a new bushing

1 to the fuel pump.

Use the new bushing to prevent fuel leakage.

VL800K5 (’05-MODEL) 101

• Install a new O-ring and apply SUZUKI SUPER GREASE “A” to it.

, 99000-25030: SUZUKI SUPER GREASE “A” (USA)

99000-25010: SUZUKI SUPER GREASE “A” (Others)

The O-ring must be replaced with a new one to prevent fuel leakage.

• When installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque, in the ascending order of numbers.

* Fuel pump mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)

NOTE:

Apply a small quantity of the THREAD LOCK to the thread portion of fuel pump mounting bolt.

- 99000-32050: THREAD LOCK “1342”

102 VL800K5 (’05-MODEL)

THROTTLE BODY

CONSTRUCTION

1 STP sensor

2 TP sensor

3 IAP sensor

4 STVA

5 Fuel delivery pipe

6 O-ring

7 Fuel injector

8 Cushion seal

9 Three way joint (only E33)

0 Hose (only E33)

A Vacuum hoses

B Fast idle screw

C Throttle stop screw

A STP sensor mounting screw

B TP sensor mounting screw

ITEM N·m kgf-m lb-ft

3.5

0.35

2.45

3.5

0.35

2.45

AIR CLEANER BOX REMOVAL

• Remove the fuel tank. (

$Page 93)

• Remove the bolts

1 and lossen the clamp screw 2.

NOTE:

“

✩

” indicates hook location.

• Disconnect the IAT sensor lead wire coupler

• Disconnect the PAIR hose

• Remove the IAP sensors (Front cylinder side inder side

6) from the mount stay.

• Remove the PCV hose

• Remove the air intake pipe

5 and Rear cyl-

7 and loosen the clamp screw 8.

AIR CLEANER BOX INSTALLATION

Installation is in the reverse order of removal.

VL800K5 (’05-MODEL) 103

104 VL800K5 (’05-MODEL)

THROTTLE BODY REMOVAL

• Remove the air intake pipe. (

$Page 103)

• Disconnect the TP sensor lead wire coupler

1, STVA lead wire coupler

2 and STP sensor lead wire coupler 3.

• Disconnect the fuel injector lead wire couplers

• Disconnect the vacuum hoses

• Loosen the throttle body clamp screw at the intake pipe side.

• Disconnect the throttle cables from their drum.

After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body.

THROTTLE BODY DISASSEMBLY

• Remove the vacuum hose

1 and fuel feed hose 2.

• Remove the clamp

• Remove the fuel delivery hose

• Remove the fuel delivery pipes

• Remove the fuel injectors

VL800K5 (’05-MODEL) 105

• Remove the TP sensor

7 with the special tool.

" 09930-11950: Torx wrench

NOTE:

Prior to disassembly, mark the TP sensor’s original position with a paint or scribe for accurate reinstallation.

106 VL800K5 (’05-MODEL)

• Remove the STP sensor

8 with the special tool.

" 09930-11950: Torx wrench

NOTE:

* Prior to disassembly, mark the STP sensor’s original position with a paint or scribe for accurate reinstallation.

* TP sensor and STP sensor look very much alike. To avoid confusion, mark identifications when removing.

Never remove the STVA

9 from the throttle body.

* Do not loosen the nut

* Do not turn the screw

* The fast idle screw

B is factory-adjusted at the time

LE unless otherwise necessary.

Never remove the secondary throttle valve

C and

throttle valve

• Remove the fuel delivery pipes

THROTTLE BODY CLEANING

Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions for proper use, handling and storage.

• Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

Do not use wire to clean passageways. Wire can damage passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Always follow the chemical manufacturer’s instructions for proper use and cleaning of the throttle body components. Do not apply carburetor cleaning chemicals to the rubber and plastic materials.

INSPECTION

• Check following items for any damage or clogging.

* O-ring

* Throttle valve

* Secondary throttle valve

* Vacuum hose

VL800K5 (’05-MODEL) 107

108 VL800K5 (’05-MODEL)

THROTTLE BODY REASSEMBLY

Reassemble the throttle body in the reverse order of disassembly. Pay attention to the following points:

• Apply thin coat of the engine oil to the new O-rings.

Replace the O-rings with the new ones.

• With the STV fully opened, install the STP sensor

1 and tighten the STP sensor mounting screw to the specified torque.

TPS and STPS resemble each other very closely in external appearance.

Make sure to check the color of coupler before installing.

STP sensor: Green color coupler

TP sensor: Black color coupler

NOTE:

* Align the secondary throttle shaft end

with the groove

of

STP sensor.

shaft end

if necessary.

, 99000-25030: SUZUKI SUPER GREASE “A” (USA)

" 09930-11950: Torx wrench

* STP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.45 lb-ft)

NOTE:

If the STP sensor adjustment is necessary, refer to page 111 for

STP sensor setting procedure.

• With the throttle valve fully closed, install the TP sensor

2 and tighten the TP sensor mounting screw to the specified torque.

NOTE:

* Align the throttle shaft end

with the groove

of TP sensor.

* Apply SUZUKI SUPER GREASE “A” to the throttle shaft end

if necessary.

TP sensor setting procedure. (

Page 118)

, 99000-25030: SUZUKI SUPER GREASE “A” (USA)

99000-25010: SUZUKI SUPER GREASE “A” (Others)

" 09930-11950: Torx wrench

* TP sensor mounting screw: 3.5 N·m (0.35 kgf-m, 2.45 lb-ft)

• Install the O-ring and dust seal to each fuel injector.

• Apply thin coat of the engine oil to the new O-ring and cushion seal.

Replace the O-ring and cushion seal with the new ones.

• Install the fuel injectors

3 by pushing them straight to each throttle body.

Never turn the injector while pushing it.

• Install the fuel delivery pipes

4 to the throttle body assembly.

Never turn the fuel injectors while installing them.

fied torque.

* Fuel delivery pipe mounting screw:

• Apply thin coat of the engine oil to the new O-rings.

Replace the O-rings with the new ones.

VL800K5 (’05-MODEL) 109

110 VL800K5 (’05-MODEL)

THROTTLE BODY INSTALLATION

Installation is in the reverse order of removal. Pay attention to the following points:

• Connect the TP sensor lead wire coupler

TP sensor lead wire coupler and STP sensor lead wire coupler resemble each other very closely in external appearance.

Make sure to check the color of coupler before installing.

TP sensor lead wire coupler: Black color

STP sensor lead wire coupler: Green color

• Connect the throttle pulling cable

2 and throttle returning cable

3 to the throttle cable drum.

• Adjust the throttle cable play. (

$VL800K1 2-11)

STP SENSOR ADJUSTMENT

If the STP sensor adjustment is necessary, measure the sensor resistance and adjust the STP sensor position as follows:

• Disconnect the STP sensor coupler.

• Close the secondary throttle valve fully by moving the fast idle link, and measure the STP sensor resistance (between Yellow wire terminal and Black wire terminal).

! STP sensor setting resistance

ST valve is fully closed: Approx. 0.5 k

Ω

(Yellow – Black)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

• Loosen the STP sensor mounting screw

• Adjust the STP sensor

2 until resistance comes to specifica-

tion and tighten the STP sensor mounting screw.

" 09930-11950: Torx wrench

* STP sensor mounting screw: 3.5 N·m

(0.35 kgf-m, 2.45 lb-ft)

FUEL INJECTOR REMOVAL

• Remove the fuel tank. (

$Page 93)

• Remove the air intake pipe. (

$Page 103)

• With battery negative cable disconnected, disconnect the injector couplers.

• Remove the fuel delivery pipes. (

$Page 105)

• Remove the fuel injectors No.1 and No.2. (

$Page105)

VL800K5 (’05-MODEL) 111

112 VL800K5 (’05-MODEL)

FUEL INJECTOR INSPECTION

Check fuel injector filter for evidence of dirt and contamination. If present, clean and check for presence of dirt in the fuel lines and fuel tank.

The fuel injector can be checked without removing it from the throttle body.

Refer to page 80 for details.

FUEL INJECTOR INSTALLATION

• Apply thin coat of the engine oil to new injector O-rings.

• Install the injector by pushing it straight to the throttle body.

Never turn the injector while pushing it.

FAST IDLE

The fast idle system is automatic type.

When the fast idle cam is turned by the secondary throttle valve actuator, the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed.

When the engine has warmed up, depending on the water temperature, ambient temperature and lapsed time, the fast idle is cancelled allowing the engine to resume idle speed.

Ambient Temp.

–5 °C (23 °F)

15 °C (59 °F)

25 °C (77 °F)

Fast idle rpm

Fast idle cancelling time

1 500 – 2 100 rpm Approx. 100 sec.

1 500 – 2 100 rpm Approx. 60 sec.

1 500 – 2 100 rpm Approx. 50 sec.

FAST IDLE ADJUSTMENT

• Lift and support the fuel tank. (

$Page 93)

• Start up the engine and run it in idling condition for warming up.

• Set the idle rpm to 1 100 rpm by the throttle stop screw

• Check and adjust the TP sensor. (

$Page 118)

• Start up the engine.

(between

+ Bl/B wire and - B/Br wire).

• Measure the TP sensor output voltage at the coupler

" 09900-25008: Multi-circuit tester set

09900-25009: Needle pointed probe set

& Tester knob indication: Voltage (')

• Turn the ignition switch OFF.

• Disconnect the STVA coupler.

• Turn the ignition switch ON.

• Open the secondary throttle valve fully by moving the fast idle link with your finger.

• With the secondary throttle valve held at this position, measure the output voltage of the TP sensor as shown.

VL800K5 (’05-MODEL) 113

114 VL800K5 (’05-MODEL)

• Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened.

Example: TP sensor output voltage with the STV fully open

Minus TP sensor output voltage at idle is 0.08 V

STV fully open

Idle

1.20 V

- 1.12 V

0.08 V

! TP sensor output voltage variation: 0.064 – 0.096 V

• If the voltage variation is out of specification, turn in or out the fast idle adjust screw

2 to adjust the voltage to specification.

The fast idle screw is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary.

• Cool down the engine to ambient air temperature and start the engine to check the fast idle rpm comes within the specified rpm.

! Standard

Fast idle rpm: 1 500 – 2 100 rpm/Cold engine

Idle rpm : 1 100 ± 100 rpm/Warmed engine

STVA.

VL800K5 (’05-MODEL) 115

THROTTLE VALVE SYNCHRONIZATION

Check and adjust the throttle valve synchronization among two cylinders.

USE OF DIGITAL VACUUM TESTER

Step 1

• Lift and support the fuel tank. (

$Page 93)

• Start up the engine and run it in idling condition for warming up.

• Stop the warmed-up engine.

• Disconnect the vacuum hose

1 from each throttle body.

• Connect the vacuum tester hose to each vacuum nipple on the throttle body with the special tools.

" 13685-02FA0: Three way joint

13681-39F00-225: Hose

*2: To each vacuum hose.

*3: To vacuum tester hose.

Step 2

• Connect a tachometer and start up the engine.

• Bring the engine rpm to 1 100 rpm by the throttle stop screw.

Avoid drawing dirt into the throttle body while running the engine without intake pipe and air cleaner box. Dirt drawn into the engine will damage the internal engine parts.

116 VL800K5 (’05-MODEL)

Step 3

• Turn in two idle air screws to the complete close position.

• Check for difference of vacuum between front cylinder and rear cylinder.

• Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower.

NOTE:

* During balancing the throttle valves, always set the engine rpm at 1 100 rpm, using throttle stop screw.

* After balancing the two valves, set the idle rpm to 1 100 rpm by the throttle stop screw.

Step 4

• Check for the synchronization adjustment. If the adjustment is not yet correct, remove each idle air screw and clean them with a spray-type carburetor cleaner and blow dry with a compressed air.

• Also, clean the idle air screw passageways.

NOTE:

* Slowly turn the idle air screw in clockwise and count the number of turns until the screw is lightly seated.

be reset correctly after cleaning.

* Make a note of how many turns were made so the screw can

proceed to the Step 3.

USE OF VACUUM BALANCER GAUGE

Calibrating each vacuum gauge

• Stop the warmed-up engine.

• Disconnect the vacuum hose

1 from the No.1 (Rear cylinder) throttle body.

• Connect one of the vacuum balancer gauge hose to the vacuum nipple on the No.1 throttle body with the special tools.

" 13685-02FA0: Three way joint

13681-39F00-225: Hose

*1: To vacuum nipple.

*2: To vacuum hose.

*3: To vacuum balancer gauge hose.

• Connect a tachometer.

• Start up the engine and keep it running at 1 100 rpm by turning throttle stop screw

Avoid drawing dirt into the throttle body while running the engine without intake pipe and air cleaner box. Dirt drawn into the engine will damage the internal engine parts.

• Turn the air screw

3 of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball

4 in the tube to the center line

NOTE:

The vacuum gauge is positioned vertical level.

• After making sure that the steel ball stays steady at the center line, disconnect the hose from the No.1 throttle body vacuum

nipple and connect the next hose to this vacuum nipple.

• Turn air screw to bring the other steel ball line.

6 to the center

tle valves.

The balancer gauge is now ready for use in balancing the throt-

Throttle valve synchronization

Using the vacuum balancer gauge, inspect the throttle valve synchronization in the same manner of the digital vacuum tester.

Pay attention to the following points:

The vacuum gauge is positioned vertical level, and in this position the two balls should be within one ball dia. If the difference is larger than one ball, turn the balance adjusting screw on the throttle body and bring the ball to the same level.

A correctly adjusted throttle valve synchronization has the balls in the No. 1 and No.2 at the same level.

" 09913-13121: Vacuum balancer gauge

NOTE:

* During balancing the throttle valves, always set the engine rpm at 1 100 rpm, using throttle stop screw.

* After balancing the two valves, set the idle rpm to 1 100 rpm by the throttle stop screw.

VL800K5 (’05-MODEL) 117

118 VL800K5 (’05-MODEL)

THROTTLE POSITION SENSOR (TPS) SETTING

After all adjustments are completed, check or adjust the TPS

1 setting condition.

VL800K5 (’05-MODEL) 119

EMISSION CONTROL SYSTEMS

FUEL INJECTION SYSTEM

VL800 motorcycles are equipped with a fuel injection system for emission level control.

This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.

1 Fuel tank

2 Fuel filter (For high pressure)

3 Fuel pressure regulator

4 Fuel delivery pipe

5 Fuel injector

6 Fuel feed hose

7 Fuel mesh filter (For low pressure)

8 Fuel pump

A Before-pressurized fuel

B Pressurized fuel

C Relieved fuel

120 VL800K5 (’05-MODEL)

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)

The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system (For E-02, -19, -24 and -33). The fresh air is drawn into the exhaust port with the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS.

1 PAIR control solenoid valve

2 PAIR reed valve

3 Air cleaner box

4 Fuel injector

5 ECM

6 HO2 sensor (E-02, 19, 24)

7 Threeway catalyst (E-02, 19, 24, 33)

A FRESH AIR

B EXHAUST GAS

VL800K5 (’05-MODEL) 121

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:

• Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases.

• Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air.

• Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label.

EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)

1 Fuel-vapor separator

2 IAP sensor

3 Throttle body

4 Fuel shut-off valve

5 EVAP Canister

6 Purge hose

A FRESH AIR

B HC VAPOR

C VACUUM

122 VL800K5 (’05-MODEL)

PAIR (AIR SUPPLY) SYSTEM AND EMISSION CONTROL SYSTEM

INSPECTION

PCV HOSE

• Remove the PCV hose from the crankcase breather cover.

• Inspect the PCV hose for wear or damage.

• If it is worn or damaged, replace the PCV hose with a new one.

PAIR HOSES

• Inspect the PAIR hoses for wear or damage.

• Inspect the PAIR hoses for secure connection.

PAIR REED VALVE

• Remove the PAIR control solenoid valve. (

$Page 123)

• Remove the PAIR reed valve.

• Inspect the reed valve for the carbon deposit.

• If the carbon deposit is found in the reed valve, replace the

PAIR reed valve with a new one.

• Install the PAIR reed valve and PAIR reed valve cover as shown.

• Install the PAIR control solenoid valve. (

$Page 123)

PAIR CONTROL SOLENOID VALVE

• Lift and support the fuel tank. (

$Page 93)

• Remove the PAIR control solenoid valve cover

• Disconnect the PAIR control solenoid valve lead wire coupler

• Disconnect the PAIR hoses.

• Remove the PAIR control solenoid valve

• Check that air flows through the air inlet port to the air outlet port.

• If air does not flow out, replace the PAIR control solenoid valve with a new one.

A Air flow

• Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow.

• If air does not flow out, the solenoid valve is in normal condition.

• Check the resistance between the terminals of the PAIR control solenoid valve.

! Resistance: 18 – 22 Ω at 20 – 30 °C (68 – 86 °F)

" 09900-25008: Multi-circuit tester set

% Tester knob indication: Resistance (Ω)

If the resistance is not within the standard range, replace the

PAIR control solenoid valve with a new one.

Installation is in the reverse order of removal.

• Connect the PAIR control solenoid valve lead wire coupler and PAIR hoses securely.

VL800K5 (’05-MODEL) 123

12V

124 VL800K5 (’05-MODEL)

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION

(Only for E-33)

• Remove the seats

1. (

$VL800K1 7-2)

• Remove the speedometer

2. (

$VL800K1 5-3)

• Remove the fuel tank

3. (

$Page 93)

• Remove the fuel frame cover

4. (

$VL800K1 7-2)

HOSES (EVAP hose)

Inspect the hoses for wear or damage.

Make sure that the hoses are securely connected.

EVAP CANISTER

Inspect the canister for damage to the body.

TIGHTENING TORQUE

CHASSIS

N·m

ITEM

Front axle

Front axle pinch bolt

Brake disc bolt

Front fork cap bolt

Front fork spring stopper nut

Front fork damper rod bolt

*Front fork upper clamp bolt

Front fork lower clamp bolt

Steering stem head nut

Front master cylinder mounting bolt

Front brake caliper mounting bolt

Brake hose union bolt

Air bleeder valve

Handlebar set bolt

Handlebar holder nut

Front footrest bolt

Frame down tube mounting bolt (M8)

Frame down tube mounting bolt (M10)

Rear brake pedal bolt

Rear swingarm pivot bolt (Left)

Rear swingarm pivot bolt (Right)

Rear swingarm pivot bolt lock nut

Rear axle nut

100

9.5

100

Rear torque link nut (front) 35

Rear torque link nut (rear)

Rear brake cam lever bolt

Driven joint stopper bolt

Frame handle grip mounting bolt (M10)

Fuel level gauge mounting bolt

7.5

kgf-m

6.5

3.5

2.5

1.0

5.0

1.0

2.3

5.0

1.1

10.0

0.95

10.0

5.0

7.8

9.0

1.0

3.9

2.3

0.75

2.3

7.0

5.5

3.5

2.0

2.3

3.3

6.5

3.3

2.3

4.5

VL800K5 (’05-MODEL) 125 lb-ft

47.0

25.5

18.0

7.3

7.0

36.0

7.0

16.5

36.0

8.0

72.5

7.0

72.5

36.0

57.5

65.0

7.0

28.0

16.5

5.5

16.5

50.5

40.0

47.0

24.0

16.5

33.1

25.5

14.5

16.5

24.0

126 VL800K5 (’05-MODEL)

WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING

200 mm

50 mm

200 mm

Clamp

Handlebar switch (L & R)

Speed sensor

Wiring harness

Clamp

Front turn signal light (L & R)

Clamp

Wiring harness

PAIR control solenoid valve leadwire

To generator

Clamp

To wiring harness

Fuse

Clamp

Ignition coil leadwire

Regulator/Rectifier

Electrical parts holder

Starter motor leadwire

Wiring harness

Generator leadwire

Clamp

After clamping, cut the excessive end.

Connect with the neutral switch in the cover.

VL800K5 (’05-MODEL) 127

Injector

To speedometer

Pass through inside of the cover

TO sensor

Clamp

IAT sensor

To HO2S sensor

Clamp

To stoplamp switch

To Horn

Wiring harness

28 mm

Frame

Radiator

128 VL800K5 (’05-MODEL)

CABLE ROUTING

Throttle cable No.2

(Returning cable)

Throttle cable No.1

(Pulling cable)

200 mm

(7.9 in)

40 mm

(1.6 in)

Wiring harness

Clamp

VL800K5 (’05-MODEL) 129

Clutch cable

Throttle

Throttle cable No.2

cable No.1

Brake hose

Wiring harness

Cable guide *1

Clutch cable

White

Cable guide

Wiring harness tape

0 – 2 mm

Throttle cable clamp

(0 – 0.08 in)

0 – 2 mm (0 – 0.08 in)

High-tension cord

Cushion

Clutch cable *3

Clamp

Clutch cable *4

Clamp

High-tension cord

Clutch cable

Throttle cable No.1

Throttle cable No.2

Wiring harness

Clamp

Clutch cable

Pass through the clutch cable and throttle cable inside the wiring harness.

Clamp the high-tension cord immediately on the side of the cushion.

Clamp the clutch cable on the frame with the cable’s white tape brought to the recess of the frame.

The clutch cable must be contacted with the cushion when clamped.

130 VL800K5 (’05-MODEL)

COOLING SYSTEM HOSE ROUTING

VL800K5 (’05-MODEL) 131

SPEED SENSOR LEAD WIRE ROUTING

Brake hose

Headlight housing

Speed sensor lead wire

Clamp

30 mm

(1.18 in)

Speed sensor guide hook

Speed sensor lead wire

Speed sensor lead guide

Pass through the speed sensor lead wire between the headlight housing and brake hose.

132 VL800K5 (’05-MODEL)

FUEL TANK INSTALLATION

Cut the clamp

Frame

VL800K5 (’05-MODEL) 133

BRAKE PEDAL INSTALLATION

5 mm (0.20 in)

98 mm (3.86 in)

*1 Apply an adhesive agent.

HANDLEBAR BALANCER

Throttle grip

Handlebar

Handle balancer expander

Handlebar balancer

Nut

Screw

5.5 N·m

(0.5 kgf-m, 4.0 lb-ft)

1 mm (0.04 in): Right side

0 mm (0 in): Left side

134 VL800K5 (’05-MODEL)

PAIR (AIR SUPPLY) SYSTEM DIAGRAM

1 PAIR control solenoid valve

2 PAIR reed valve

A FRESH AIR

*1 From air cleaner.

*2 To #1 cylinders.

*3 To #2 cylinders.

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING

VL800K5 (’05-MODEL) 135

1 PAIR control solenoid valve

Throttle body

Bolt

To air cleaner box.

*2 Matching mark

Do not contact the hose and throttle cable drum.

The sealant side should face PAIR pipe side.

With the bolt lightly contacted with the

PAIR pipe, tighten the bolt.

136 VL800K5 (’05-MODEL)

EVAP CANISTER HOSE ROUTING (Only for E-33)

1 Three way joint

Wiring harness

3 Frame

4 Fuel shut-off valve

5 EVAP Canister

Pass through the purge hose over the wiring harness.

*2 White paint mark should face upside.

*3 To three way joint.

VL800K5 (’05-MODEL) 137

SPECIAL TOOLS

09900-25009

Needle pointed probe set

09904-41010

SDS Set

99565-01010-004

CD-ROM Ver.4

09913-13121

Vacuum balancer gauge

09930-11950

Torx wrench

09940-40211 09940-40220

Fuel pressure gauge Fuel pressure gauge 09930-82720

Mode select switch adaptor hose attachment

NOTE:

When ordering the special tool, please confirm whether it is available or not.

138 VL800K5 (’05-MODEL)

WIRE COLOR

B : Black

Bl : Blue

Br : Brown

Dg : Dark green

G : Green

B/Bl

B/G

B/R

B/Y

Bl/G

Bl/W

Br/B

G/B

Gr/B

Gr/W

O/B

O/R

O/Y

R/Bl

W/Bl

Y/B

Y/G

Y/W

Gr : Gray

Lbl : Light blue

Lg : Light green

O : Orange

P : Pink

R : Red

W : White

Y : Yellow

: Black with Blue tracer

: Black with Green tracer

: Black with Red tracer

: Black with Yellow tracer

: Blue with Green tracer

: Blue with White tracer

: Brown with Black tracer

: Green with Black tracer

: Gray with Black tracer

: Gray with White tracer

B/Br

B/Lg

B/W

Bl/B

Bl/R

Bl/Y

Br/W

G/Y

G/W

Gr/R

: Black with Brown tracer

: Black with Light green tracer

: Black with White tracer

: Blue with Black tracer

: Blue with Red tracer

: Blue with Yellow tracer

: Brown with White tracer

: Green with Yellow tracer

: Green with White tracer

: Gray with Red tracer

: Orange with Black tracer O/Bl : Orange with Blue tracer

: Orange with Red tracer

: Orange with Yellow tracer

: Red with Blue tracer

O/G

O/W

P/W

: White with Blue tracer

: Yellow with Black tracer

: Yellow with Green tracer

: Yellow with White tracer

W/B

W/R

: Orange with Green tracer

: Orange with White tracer

: White with Black tracer

: White with Red tracer

: Yellow with Blue tracer

: Yellow with Red tracer

WIRING DIAGRAM

E-02, 19, 24

Wiring diagrams wire color, refer to section “WIRE COLOR”.

TEMP

OIL

: ENGINE COOLANT TEMP. WARNING LIGHT

: FI LIGHT

: FUEL WARNING LIGHT

: TURN SIGNAL INDICATOR LIGHT

: HI-BEAM INDICATOR LIGHT

: NEUTRAL INDICATOR LIGHT

: OIL INDICATOR LIGHT

SPEED

SENSOR

SPEEDOMETER

HANDLEBAR SWITCH (R)

FI/TEMP/OIL

HAZARD

SWITCH

OFF

RUN

ENGINE

STOP

SWITCH

OFF

RUN

STARTER

BUTTON

PUSH

FRONT BRAKE

SWITCH

OFF

REAR BRAKE

SWITCH

OFF

SENSOR

IGNITION

COIL (R)

IGNITION

COIL (F)

OPTION

HO2

SENSOR

FUEL

PUMP

FUEL PUMP

RELAY

ECM

FRONT

TURN SIGNAL

LIGHT (R)

HEADLIGHT

FRONT

TURN SIGNAL

LIGHT (L)

POSITION

LIGHT

(Except for E-24)

HORN

OFF

COOLING

FAN

THERMO-

SWITCH

COOLING

FAN

MOTOR

PUSH

HORN

BUTTON

PUSH

PASSING

LIGHT

SWITCH

PUSH

TURN SIGNAL

LIGHT SWITCH

DIMMER

SWITCH

FREE

CLUTCH

SWITCH

HANDLEBAR SWITCH (L)

LOCK

OFF

IGNITION SWITCH

SWITCH

OIL PRESSURE

SWITCH

PUSH

FREE

SIDE STAND

SWITCH

B Bl

FUSE BOX

1. HEAD HI

2. HEAD LO

3. FUEL

4. IGNITION

5. SIGNAL

6. POWER SOURCE

10 A

15 A

10 A

INJECTOR (F)

INJECTOR (R)

PAIR

SOLENOID

IAP

SENSOR(R)

IAP

SENSOR(F)

ECT

SENSOR

STV

ACTUATOR

STP

SENSOR

IAT

SENSOR

CKP

SENSOR

GENERATOR

REGULATOR/

RECTIFIER

STARTER

MOTOR

1: MAIN (30A)

STARTER

RELAY

BATTERY

REAR TURN

SIGNAL LIGHT (R)

BRAKE LIGHT

/ TAILLIGHT

REAR TURN

SIGNAL LIGHT (L)

E-03, 28, 33

TEMP

OIL

: ENGINE COOLANT TEMP. WARNING LIGHT

: FI LIGHT

: FUEL WARNING LIGHT

: TURN SIGNAL INDICATOR LIGHT

: HI-BEAM INDICATOR LIGHT

: NEUTRAL INDICATOR LIGHT

: OIL INDICATOR LIGHT

SPEED

SENSOR

SPEEDOMETER

HANDLEBAR SWITCH (R)

FI/TEMP/OIL

F HAZARD

SWITCH

ENGINE

STOP

SWITCH

OFF

RUN

OFF

RUN

STARTER

BUTTON

PUSH

FRONT BRAKE

SWITCH

OFF

REAR BRAKE

SWITCH

OFF

SENSOR

IGNITION

COIL (R)

IGNITION

COIL (F)

OPTION

SENSOR

FUEL

PUMP

FUEL PUMP

RELAY

ECM

FRONT

TURN SIGNAL

LIGHT (R)

HEADLIGHT

FRONT

TURN SIGNAL

LIGHT (L)

HORN

OFF

COOLING

FAN

THERMO-

SWITCH

FREE

COOLING

FAN

MOTOR

PUSH

HORN

BUTTON

PUSH

PASSING

LIGHT

SWITCH

PUSH

TURN SIGNAL

LIGHT SWITCH

DIMMER

SWITCH

CLUTCH

SWITCH

HANDLEBAR SWITCH (L)

LOCK

OFF

IGNITION SWITCH GP

SWITCH

OIL PRESSURE

SWITCH

PUSH

FREE

SIDE STAND

SWITCH

B Bl

FUSE BOX

1. HEAD HI

2. HEAD LO

3. FUEL

4. IGNITION

5. SIGNAL

6. POWER SOURCE

10 A

15 A

10 A

INJECTOR (F)

INJECTOR (R)

PAIR

SOLENOID

IAP

SENSOR(R)

IAP

SENSOR(F)

ECT

SENSOR

STV

ACTUATOR

STP

SENSOR

IAT

SENSOR

CKP

SENSOR

GENERATOR

REGULATOR/

RECTIFIER

STARTER

MOTOR

1: MAIN (30A)

STARTER

RELAY

BATTERY

REAR TURN

SIGNAL LIGHT (R)

BRAKE LIGHT

/ TAILLIGHT

REAR TURN

SIGNAL LIGHT (L)

Prepared by

Part No.99501-38080-01E

Printed in Japan

158

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Printed in Japan

K5

BOTTOM

USE THIS MANUAL WITH:

VL800 SERVICE MANUAL (99500-38043-01E)

9 9 5 0 1 - 3 8 0 8 0 - 0 1 E

Hi! I've reviewed the Suzuki Intruder VL800 Supplementary Service Manual. This document details service specifications, data, FI system features, troubleshooting procedures, and wiring diagrams specific to the VL800K5 model. I'm ready for your questions.

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Key features

805cc V-twin engine for ample torque and a smooth ride
Comfortable seat and low center of gravity for a relaxed riding position
Stylish design with classic lines and modern touches
Easy to maneuver and handle, making it a great choice for beginners and experienced riders alike
Fuel-efficient, allowing you to travel longer distances without frequent stops
Reliable and durable, ensuring years of riding enjoyment

Frequently asked questions

The Suzuki Intruder VL800 has an 805cc V-twin engine.

Yes, the Suzuki Intruder VL800 has a comfortable seat and a low center of gravity, making it a great choice for long rides.

Yes, the Suzuki Intruder VL800 is fuel-efficient, allowing you to travel longer distances without frequent stops.

Yes, the Suzuki Intruder VL800 is easy to maneuver and handle, making it a great choice for beginners and experienced riders alike.

Yes, the Suzuki Intruder VL800 is reliable and durable, ensuring years of riding enjoyment.

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Printed in Japan

K5

BOTTOM

IMPORTANT

All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to

Environmental Protection agency emission regulations.

These regulations set specific standards for exhaust

requirements. This manual includes specific information required to properly inspect and service VL800 in accordance with all EPA regulations. It is strongly

Periodic Servicing and FI System and Fuel System be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA

program can be found in the U.S. SUZUKI EMISSION

CONTROL PROGRAM MANUAL/SERVICE BULLETIN.

VL800K5 (’05-MODEL)

This manual described the service specifications, service data, FI system and servicing procedurers which differ from those of the VL800K4 (’04-MODEL).

NOTE:

* Any differences between the VL800K4 (’04-MODEL) and VL800K5 (’05-MODEL) in specifications and service data are cleary indicated with an asterisk (*) mark.

* Please refer to the service manual for details which are not given in this manual.

CONTENTS

COUNTRY AND AREA CODES

SPECIFICATIONS

ABBREVIATIONS USED IN THIS

MANUAL

A

E

B

F

C

D

H

I

G

L

M

N

O

P

R

S

T

SAE-TO-FORMER SUZUKI TERM

SERVICE DATA

VALVE + GUIDE

CAMSHAFT + CYLINDER HEAD

CONROD + CRANKSHAFT

OIL PUMP

CLUTCH

TRANSMISSION

SHAFT DRIVE

THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT

* INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

* FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR

* THROTTLE BODY

ELECTRICAL

WATTAGE

BRAKE + WHEEL

TIRE

SUSPENSION

FUEL + OIL

PERIODIC MAINTENANCE CHART

NOTE:

I=Inspect and clean, adjust, replace or lubricate as necessary;

R=Replace; T=Tighten

ENGINE IDLE SPEED

NOTE:

Warm up the engine before adjusting the engine idle speed.

PRECAUTIONS IN SERVICING

ELECTRICAL PARTS

FUSE

ECM/VARIOUS SENSORS

ELECTRICAL CIRCUIT INSPECTION

PROCEDURE

NOTE:

If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts. Otherwise, diagnosis will be misled.

USING THE MULTI-CIRCUIT TESTER

NOTE:

* When connecting the multi-circuit tester, use the needle connect the probes of tester to them.

* Use the needle pointed probe to prevent the rubber of the water proof coupler from damage.

FI SYSTEM TECHNICAL FEATURES

INJECTION TIME (INJECTION VOLUME)

COMPENSATION OF INJECTION TIME (VOLUME)