2006-2014 SUZUKI VZR1800 Service Manual

VZR1800

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 DRIVELINE/AXLE 4 FI SYSTEM DIAGNOSIS 5 FUEL SYSTEM AND THROTTLE BODY 6 EXHAUST SYSTEM 7 COOLING AND LUBRICATION SYSTEM 8 CHASSIS 9 ELECTRICAL SYSTEM 10 SERVICING INFORMATION 11 EMISSION CONTROL INFORMATION 12 FOREWORD This manual contains an introductory description on the SUZUKI VZR1800 and procedures for its inspection/service and overhaul of its main compo- nents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service.  © COPYRIGHT SUZUKI MOTOR CORPORATION 2006 * This manual has been prepared on the basis of the latest specifications at the time of publi- cation. If modifications have been made since then, differences may exist between the con- tent of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcy- cles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. 99500-39293-03E

SUPPLEMENTS VZR1800 ('07-MODEL) VZR1800 ('08-MODEL) 13 14 15 VZR1800/NK9 (’09-MODEL) 16 VZR1800N ('08-MODEL) WIRING DIAGRAM 17

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel 1 Brake disc 2 Dust seal 3 Bearing 4 Spacer 5 Collar 6 Front wheel A Front axle B Brake disc bolt " ITEM N·m kgf-m lb-ft A 100 10.0 72.5 B 23 2.3 16.5

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK SUPER “1360” or equivalent. 99000-32130 Apply oil. Use engine oil unless otherwise specified. Use engine coolant or equivalent. 99000-99032-11X Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Use fork oil or equivalent. 99000-99044-L01 Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply or use brake fluid. Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Measure in voltage range. Apply SUZUKI SILICON GREASE or equivalent. 99000-25100 Measure in current range. Apply SUZUKI BOND “1215” or equivalent. 99000-31110 Measure in resistance range. Apply SUZUKI BOND “1207B” or equivalent. 99000-31140 Measure in diode test range. Apply THREAD LOCK SUPER “1303” or equivalent. 99000-32030 Measure in continuity test range. Apply THREAD LOCK SUPER “1322” or equivalent. 99000-32110 Use special tool. Apply THREAD LOCK “1342” or equivalent. 99000-32050 Indication of service data.

ABBREVIATIONS USED IN THIS MANUAL A ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center A/F : Air Fuel Mixture B BBDC : Before Bottom Dead Center BTDC : Before Top Dead Center B+ : Battery Positive Voltage C CKP Sensor : Crankshaft Position Sensor (CKPS) CKT : Circuit CLP Switch : Clutch Lever Position Switch (Clutch Switch) CO : Carbon Monoxide CPU : Central Processing Unit D DC : Direct Current DMC : Dealer Mode Coupler DOHC : Double Over Head Camshaft DRL : Daytime Running Light DTC : Diagnostic Trouble Code E ECM : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) EVAP : Evaporative Emission EVAP Canister : Evaporative Emission Canister (Canister) EXC System : Exhaust Control System (EXCS) EXC Valve : Exhaust Control Valve (EXCV) EXCV Actuator : Exhaust Control Valve Actuator (EXCVA) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay G GEN : Generator GND : Ground GP Switch : Gear Position Switch H HC : Hydrocarbons I IAP Sensor : Intake Air Pressure Sensor (IAPS) (MAP Sensor) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition ISC Valve : Idle Speed Control Valve (ISCV) L LCD : Liquid Crystal Display LED : Light Emitting Diode (Malfunction Indicator Lamp) LH : Left Hand M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (LED) Min : Minimum N NOX : Nitrogen Oxides

O OHC : Over Head Camshaft OPS : Oil Pressure Switch P PCV : Positive Crankcase Ventilation (Crankcase Breather) R RH : Right Hand ROM : Read Only Memory S SAE : 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 : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)

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. SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION A Air Cleaner ACL Air Cleaner, Air Cleaner Box B Barometric Pressure BARO Barometric Pressure, Atmospheric Pressure (APS, AP Sensor) Battery Positive Voltage B+ Battery Voltage, +B C Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS), Crank Angle D Data Link Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM –––– Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code E Electronic Ignition El –––– Engine Control Module ECM Engine Control Module (ECM) Fl Control Unit, Engine Control Unit (ECU) Engine Coolant Level ECL Coolant Level Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem- perature Water Temperature Engine Oil Temperature EOT Oil Temperature, Engine Oil Temperature Engine Speed RPM Engine Speed (RPM) Evaporative Emission EVAP Evaporative Emission Evaporative Emission Canister EVAP Canister –––– (Canister) Exhaust Control System EXCS EXC System (EXCS) Exhaust Control Valve EXCV EXC Valve (EXCV) Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA) Purge Valve Purge Valve Purge Valve (SP Valve) F Fan Control FC –––– Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge Fuel Pump FP Fuel Pump (FP)

SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION G Generator GEN Generator Ground GND Ground (GND, GRD) H Heated Oxygen Sensor HO2S Heated Oxygen Sensor (HO2S), O2 Sensor I Idle Speed Control ISC –––– Idle Speed Control Valve –––– ISC Valve Ignition Control IC Electronic Spark Advance (ESA) Ignition Control Module ICM –––– Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera- ture M Malfunction Indicator Lamp MIL LED Lamp Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum Mass Air Flow MAF Air Flow O On-Board Diagnostic OBD Self-Diagnosis Function Diagnostic Open Loop OL –––– P Programmable Read Only Memory PROM –––– Pulsed Secondary Air lnjection PAIR Pulse Air Control (PAIR) R Random Access Memory RAM –––– Read Only Memory ROM ROM S Secondary Air Injection AIR –––– Secondary Throttle Control Sys- tem STCS STC System (STCS) Secondary Throttle Valve STV ST Valve (STV) Secondary Throttle Valve Actuator STVA STV Actuator (STVA) T Throttle Body TB Throttle Body (TB) Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

2006-2014 SUZUKI VZR1800 Service Manual

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