Suzuki VL 800 Owner Manual
Suzuki VL 800 is an advanced motorcycle that combines power, style, and user-friendly features. With its fuel-injected engine, this bike delivers smooth and responsive performance, ensuring a thrilling ride. The electric starter allows for effortless ignition, while the halogen headlight and LED taillight enhance visibility for safer night-time riding. Whether navigating city streets or exploring open roads, the VL 800 offers a versatile and enjoyable riding experience.
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ELECTRICAL SYSTEM 8-1
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ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING .............................................................. 8- 2
LOCATION OF ELECTRICAL COMPONENTS ............................... 8- 4
CHARGING SYSTEM ....................................................................... 8- 6
TROUBLESHOOTING .................................................................. 8- 6
INSPECTION ................................................................................. 8- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION
INTERLOCK SYSTEM ..................................................................... 8-10
TROUBLESHOOTING .................................................................. 8-10
STARTER MOTOR REMOVAL AND DISASSEMBLY .................. 8-11
STARTER MOTOR INSPECTION ................................................. 8-12
STARTER MOTOR REASSEMBLY .............................................. 8-12
STARTER RELAY INSPECTION .................................................. 8-13
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ................................................................................. 8-14
IGNITION SYSTEM ........................................................................... 8-16
TROUBLESHOOTING .................................................................. 8-16
INSPECTION ................................................................................. 8-18
SPEEDOMETER .............................................................................. 8-21
REMOVAL ..................................................................................... 8-21
PARTS NAMES ............................................................................. 8-22
OPERATING PROCEDURE ......................................................... 8-22
INSPECTION ................................................................................. 8-24
LAMPS.............................................................................................. 8-28
RELAYS ............................................................................................ 8-29
SWITCHES ....................................................................................... 8-29
BATTERY ......................................................................................... 8-31
SPECIFICATIONS ......................................................................... 8-31
INITIAL CHARGING ...................................................................... 8-31
SERVICING ................................................................................... 8-32
RECHARGING OPERATION ........................................................ 8-33
8
8-2 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
• When disconnecting a connector, be sure to hold the terminals; do not pull the lead wires.
• When connecting a connector, push it in so it is firmly attached.
• Inspect the connector for corrosion, contamination and any breakage in the cover.
COUPLERS
• With a lock-type coupler, be sure to release the lock before disconnecting it. When connecting a coupler, push it in until the lock clicks shut.
• When disconnecting a coupler, be sure to hold the coupler; do not pull the lead wires.
• Inspect each terminal on the coupler for looseness or bends.
• Inspect each terminal for corrosion and contamination.
CLAMPS
• Refer to the “WIRE HARNESS ROUTING” section for proper clamping procedures. (
!
9-13 and 9-14)
• Bend the clamp properly, as shown in the illustration.
• When clamping the wire harness, do not allow it to hang down.
• Do not use wire or any substitutes for the band-type clamp.
FUSES
• When a fuse blows, always investigate the cause, correct the problem, and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use any substitutes for the fuse (e.g., wire).
SEMICONDUCTOR EQUIPPED PARTS
• Do not drop any part that contains a semiconductor (e.g., ignitor unit, regulator/rectifier).
• When inspecting the part, follow the inspection instructions carefully. Neglecting proper procedures may cause this part to be damaged.
BATTERY
• The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment).
• During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery.
• Be sure to recharge the battery in a well-ventilated and open area.
• Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery.
CONNECTING THE BATTERY
• When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the battery lead wire, first.
• When connecting the battery lead wires, be sure to connect the + battery lead wire, first.
• If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush.
• After connecting the battery, apply a light coat of grease to the battery terminals.
• Install the cover over the + battery terminal.
WIRING PROCEDURE
• Properly route the wire harness according to the “WIRE ROUT-
ING” section. (
!
9-13 to 9-14)
USING THE MULTI CIRCUIT TESTER
• Properly use the multi circuit tester + and probes. Improper use can cause damage to the motorcycle and tester.
• If the voltage and current values are not known, begin measuring in the highest range.
• When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged.
• After using the tester, be sure to turn the switch to the OFF position.
"
Before using the multi circuit tester, read its instruction manual.
ELECTRICAL SYSTEM 8-3
8-4 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
1 Ignition switch
2 Ignition coil #2
3 Fuel level gauge
4 Rear brake switch
5 Cooling fan
6 Cooling fan thermo-switch
7 Speedometer sensor
ELECTRICAL SYSTEM 8-5
8 Ignition coil #1
9 Throttle position sensor
0 Starter relay/main fuse
A Battery
B Ignitor
C Engine coolant temperature sensor
D Horn
E Starter motor
F Oil pressure switch
G Generator
H Gear position switch
I Side-stand switch
J Fuse box
K Turn signal side-stand relay
L Regulator/rectifier
8-6 ELECTRICAL SYSTEM
CHARGING SYSTEM
Generator
Y
Y
Y
B
B
B
Regulator / rectifier
B/R
B/R
Ig.switch
Fuse
IC
SCR
TROUBLESHOOTING
Battery runs down quickly.
Check accessories which use excessive amounts of electricity.
No accessories
Check the battery for current leaks. (
!
8-7)
No current leaks
Measure the charging voltage between the battery terminals.
(
!
8-8)
Incorrect
Measure the continuity of the generator coil.
(
!
8-8)
Continuity
Continued on next page
Accessories are installed
Current leaks
Correct
No continuity
• Remove accessories.
• Short circuit of wire harness
• Faulty electrical equipment
• Faulty battery
• Abnormal driving condition
• Faulty generator coil or disconnected lead wires
ELECTRICAL SYSTEM 8-7
Measure the generator no-load voltage. (
!
8-8)
Correct
Inspect the regulator/rectifier.
(
!
8-9)
Correct
Inspect wirings.
Correct
Others
Battery overcharge
Incorrect
Incorrect
Incorrect
• Faulty generator
• Faulty regulator/rectifier
• Short circuit of wire harness
• Poor contact of couplers
• Faulty battery
• Faulty regulator/rectifier
• Faulty battery
• Poor contact of generator lead wire coupler
INSPECTION
BATTERY CURRENT LEAKAGE
• Remove the two seats. (
!
7-2)
• Turn the ignition switch to the OFF position.
• Disconnect the battery lead wire.
Measure the current between battery terminal and the battery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
#
09900-25008: Multi circuit tester set
$
Battery current (leak): Under 3 mA
%
Tester knob indication: Current (
&
, 20 mA)
"
* Because the current leak might be large, turn the tester to high range first to avoid tester damage.
* Do not turn the ignition switch to the “ON” position when measuring current.
When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part.
+
DCmA
-
Battery
8-8 ELECTRICAL SYSTEM
REGULATED VOLTAGE
• Remove the two seats. (
!
7-2)
• Start the engine and keep it running at 5 000 r/min. with lighting switch turned ON (except for E-03, 28, 24, 33 models) and dimmer switch turned HI position.
Measure the DC voltage between the + and battery terminals using the multi circuit tester. If the voltage is not within the specified value, inspect the generator and regulator/rectifier.
(
!
8-8 and 8-9)
NOTE:
When making this test, be sure that the battery is in fully-charged condition.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Voltage (
&
)
$
Charging output (Regulated voltage):
14.0 – 15.5 V at 5 000 r/min.
GENERATOR COIL RESISTANCE
• Remove the secondary gear case cover.
• Disconnect the generator coupler.
Measure the resistance between the three lead wires.
If the resistance is not specified value, replace the stator with a new one. Also, check that the generator core is insulated.
#
09900-25008: Multi circuit tester set
'
Tester knob indication: Resistance (
Ω
)
$
Generator coil resistance: 0.2 – 1.5 Ω (Yellow – Yellow)
∞ Ω (Yellow – Ground)
NOTE:
When making above test, it is not necessary to remove the generator.
GENERATOR NO-LOAD PERFORMANCE
• Start the engine and keep it running at 5 000 r/min.
Using the multi circuit tester, measure the voltage between three lead wires.
If the tester reads under the specified value, replace the generator with a new one.
#
09900-25008: Multi circuit tester set
(
Tester knob indication: Voltage (
∼∼∼∼∼
)
$
Generator no-load performance (When engine is cold): More than 70 V at 5 000 r/min
-
Battery
+
DCV
Y
Y
Y
Y
Y
Y
ELECTRICAL SYSTEM 8-9
REGULATOR/RECTIFIER
• Remove the secondary gear case cover.
• Disconnect the regulator/rectifier couplers.
Measure the voltage between the lead wires using the multi circuit tester as indicated in the table below. If the voltage is not within the specified valve, replace the regulator/rectifier with a new one.
#
09900-25008: Multi circuit tester set
)
Tester knob indication: Diode test (
*
)
Unit: V
+ Tester probe
B/R
1
B/R
1
B/R
2
B
1
B
2
B
3
B/W
1
B/W
2
0
B/R
2
B
1
B
2
B
3
B/W
1
B/W
2
0 0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2
0.4 – 0.7 0.4 – 0.7 0.4 – 0.7 0.5 – 1.2 0.5 – 1.2
0.4 – 0.7 0.4 – 0.7
0.4 – 0.7 0.4 – 0.7
0.4 – 0.7 0.4 – 0.7
0
0
More than 1.4 V (tester’s battery voltage)
NOTE:
If the tester reads under 1.4 V when the tester probes are not connected, replace the battery of multi circuit tester.
WIRE COLOR
B: Black, B/R: Black with Red tracer,
B/W: Black with White tracer
B
2
B
1
B
3
B/W
1
B/R
1
B/R
2
B/W
2
8-10 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM
Starter motor
Starter relay
B/W
To ignition coils and ignitor
Y/B B/Y
Clutch lever position switch
Y/G
O/W
Engine stop switch
O/B
Starter button
Ignition switch
Fuse
(15A)
Bl
Turn signal/ side-stand relay
G side-stand switch
R
Fuse(30A)
Gear position switch
TROUBLESHOOTING
Starter motor will not run.
The transmission is in neutral. Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN” position and listen for a click from the starter relay when the starter button is pushed.
No click
Measure the starter relay voltage at the starter relay connectors (between Y/B + and B/W ) when the starter button is pushed.
Voltage
Clicks
No voltage
Check if the starter motor runs when its terminal is connected to the battery + terminal (Do not use thin “wire” because a large amount of current flows)
Runs Does not run
• Faulty starter motor
• Faulty starter relay
• Loose or disconnected starter motor lead wire
• Faulty ignition switch
• Faulty engine stop switch
• Faulty clutch lever position switch
• Faulty gear position switch
• Faulty turn signal/side-stand relay
• Faulty starter button
• Poor contact of connector
• Open circuit in wire harness
Continued on next page
ELECTRICAL SYSTEM 8-11
Check the starter relay.
(
!
8-13)
Incorrect • Faulty starter relay
Correct
• Poor contact of the starter relay
The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.
Check the side-stand switch.
(
!
8-14)
Incorrect • Faulty side-stand switch
Correct
• Open circuit in wire harness
• Poor contact of connector
Others
Engine does not turn though the starter motor runs.
• Faulty starter clutch
STARTER MOTOR REMOVAL AND
DISASSEMBLY
• Drain engine coolant. (
!
2-13)
• Remove the muffler (No.1) 1 . (
!
3-5)
• Remove the engine coolant pipe 2 . (
!
3-13)
• Remove the starter motor cover 3 .
• Remove the engine coolant inlet 4 .
• Remove the starter motor. (
!
3-14)
• Disassemble the starter motor as shown in the illustration.
1 O-ring
2 Housing end (inside)
3 Starter motor case
4 Armature
5 Brush holder
6 Housing end (outside)
8-12 ELECTRICAL SYSTEM
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder.
If any damages are found, replace the brush assembly with a new one.
COMMUTATOR
Inspect the commutator for discoloration, abnormal wear or undercut A .
If abnormal wear is found, replace the armature with a new one.
If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator 1 with a saw blade.
ARMATURE COIL INSPECTION
Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
OIL SEAL INSPECTION
Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
STARTER MOTOR REASSEMBLY
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
• Apply grease to the lip of the oil seal.
For U.S.A.
-
99000-25030: SUZUKI SUPER GREASE “A”
For the other countries
-
99000-25010: SUZUKI SUPER GREASE “A”
• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.
.
99000-25140: SUZUKI MOLY PASTE
• Align the tonque 1 on the brush holder with the groove 2 on the housing end.
• Align the threaded parts 3 on the housing end.
• Apply a small quantity of THREAD LOCK “1342” to the starter motor housing bolts.
/
99000-32050: THREAD LOCK “1342”
• Apply SUZUKI SUPER GREASE “A” to the O-ring.
For U.S.A.
-
99000-25030: SUZUKI SUPER GREASE “A”
For the others
-
99000-25010: SUZUKI SUPER GREASE “A”
STARTER RELAY INSPECTION
• Remove the two seats. (
!
7-2)
• Disconnect the battery lead wire from the battery.
• Remove the starter relay cover.
• Disconnect the starter motor lead wire 1 , battery lead wire 2 and starter relay coupler 3 .
• Remove the starter relay 4 .
Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester. If the starter relay clicks and continuity is found, the relay is ok.
#
09900-25008: Multi circuit tester set
+
Tester knob indication: Continuity test (
,
)
"
Do not apply a battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and damaged.
ELECTRICAL SYSTEM 8-13
8-14 ELECTRICAL SYSTEM
Measure the relay coil resistance between the terminals using the multi circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.
"
09900-25008: Multi circuit tester set
#
Starter relay resistance: 3 – 7
Ω
SIDE STAND/IGNITION INTERLOCK SYSTEM
PARTS INSPECTION
Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one.
SIDE-STAND SWITCH
• Remove the secondary gear case cover.
• Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White lead wires.
"
09900-25008: Multi circuit tester set
$
Tester knob indication: Diode test (
%
)
More than 1.4 V
(Tester's battery voltage)
NOTE:
If the tester reads under 1.4V when the tester probes are not connected, replace its battery.
GEAR POSITION SWITCH
• Remove the secondary gear case cover.
• Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmission in
“NEUTRAL”.
!
When disconnecting and connecting the gear position switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

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Key features
- 805cc V-twin engine produces plenty of power and torque
- Comfortable riding position makes it easy to ride for hours on end
- Fuel-injected engine provides smooth and efficient power delivery
- Digital speedometer provides accurate and easy-to-read speed information
- Low seat height makes it easy to get on and off the bike