Suzuki VL 800 (2020) User guide

IMPORTANT

FOREWORD



WARNING/CAUTION/

NOTICE

Please read this manual and fol­low its instructions carefully. To
emphasize special information,
the symbol
WAR NING, CAUTION, NOTICE
and NOTE have special mean-
ings. Pay particular attention to
messages highlighted by these
signal words:

/NOTE

 and the words

 WARNING

Indicates a potential hazard
that could result in death or
serious injury.

 CAUTION

Indicates a potential hazard
that could result in minor or
moderate injury.

NOTICE

Indicates a potential hazard
that could result in vehicle or
equipment damage.

NOTE: Indicates special informa­tion to make maintenance easier
or instructions clearer.

Motorcycling is one of the most
exhilarating sports and to ensure
your riding enjoyment, you should
become thoroughly familiar with
the information presented in this
Owner’s Manual before riding the
motorcycle.

The proper care and maintenance
that your motorcycle requires is
outlined in this manual. By follow­ing these instructions explicitly
you will ensure a long trouble-free
operating life for your motorcycle.
This motorcycle also conforms to
the U.S. Environmental Protection
Agency (EPA) and California Air
Resource Board (CARB) emis­sion regulations which apply to
new motorcycles. The proper
adjustment of engine components
is necessary for this motorcycle to
comply with the EPA and CARB
regulations. Therefore, please fol­low the maintenance instructions
closely to ensure emission com­pliance. Your authorized Suzuki
dealer has experienced techni­cians that are trained to provide
your machine with the best possi­ble service with the right tools and
equipment.

All information, illustrations, and
specifications contained in this
manual are based on the latest
product information available at
the time of publication. Due to
improvements or other changes,
there may be some discrepan­cies between information in this
manual and your motorcycle.
Suzuki reserves the right to make
production changes at any time,
without notice and without incur­ring any obligation to make the
same or similar changes to vehi­cles previously built or sold.

Suzuki Motor Corporation
believes in conservation and pro­tection of Earth’s Natural
resources. To that end, we
encourage every vehicle owner to
recycle, trade in, or properly dis­pose of, as appropriate, used
motor oil, engine coolant, and
other fluids, batteries, and tires.

TABLE OF CONTENTS

THE SPORT OF MOTORCYCLING

FUEL, OIL AND COOLANT RECOMMENDATIONS

CONTROLS, EQUIPMENT AND ADJUSTMENTS

BREAK-IN AND INSPECTION BEFORE RIDING

RIDING TIPS

ACCESSORY USE AND MOTORCYCLE LOADING

INSPECTION AND MAINTENANCE

TROUBLESHOOTING

STORAGE PROCEDURE AND MOTORCYCLE CLEANING

1

2

3

4

5

6

7

8

9

CONSUMER INFORMATION

SPECIFICATIONS

INDEX

10

THE SPORT OF MOTORCYCLING

MOST ACCIDENTS CAN BE AVOIDED ............................................................. 1-2

IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND

WEAR IT EVERY TIME YOU RIDE ..................................................................... 1-3

IF A COLLISION IS IMMINENT, DO SOMETHING! ........................................... 1-3

SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......................................... 1-4

KNOW YOUR LIMITS .......................................................................................... 1-5

BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS ........................ 1-5

PRACTICE AWAY FROM TRAFFIC ................................................................... 1-6

INSPECTION BEFORE RIDING .......................................................................... 1-6

ACCESSORIES AND LOADING ......................................................................... 1-6

CARRYING A PASSENGER ............................................................................... 1-6

MOTORCYCLE SAFETY FOUNDATION’S
“RIDING TIPS AND PRACTICE GUIDE” HANDBOOK

(FOR OWNERS IN USA) .....................................................................................1-7

BE STREET SMART ........................................................................................... 1-7

LABELS ............................................................................................................... 1-7

CONCLUSION ..................................................................................................... 1-7

1

1-1

THE SPORT OF
MOTORCYCLING

Your motorcycle and this owner’s
manual have been designed by
people like you who enjoy motor­cycling. People become motorcy­clists for many reasons. For
starters, street riding is fun and
invigorating. But no matter why
you became a motorcyclist, or
how experienced you are, you will
eventually face some challenging
situations.

In preparing for these challenges,
you will be fine-tuning your coordi­nation, concentration, and atti­tude. Learning the skills and
strategies associated with motor­cycling is the basis for safely par­ticipating in this sport. Many
motorcyclists find that as they
become better riders, they also
get more enjoyment from the free­dom unique to motorcycling.

MOST ACCIDENTS CAN BE AVOIDED

The most common type of motor­cycle accident in the U.S. occurs
when a car traveling toward a
motorcycle turns left in front of the
motorcycle. Is that because other
drivers are out to get motorcy­clists? No. Other drivers simply
don’t always notice motorcyclists.
Ride defensively. Wise motorcy­clists use a strategy of assuming
they are invisible to other drivers,
even in broad daylight. Pay care­ful attention to other motorists,
especially at intersections,
because they may not be paying
attention to you. Select a lane
position that gives you the best
view of others, and other motor­ists the best view of you. Wear
bright, reflective clothing. Put
reflective strips on your helmet.

Please remember:

1-2

IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND WEAR IT EVERY TIME YOU RIDE

Most accidents occur within a few
miles of home, and almost half
occur at speeds of less than 30
mph. So even if you’re just going
on a quick errand, be prepared­strap on your helmet before you
take off.

Helmets do not reduce essential
vision or hearing. Generally, hel­mets do not cause or intensify
injury if you crash. Helmets simply
help your skull protect your intelli­gence, your memory, your per­sonality, and your life.

IF A COLLISION IS IMMINENT, DO SOMETHING!

Many riders fear locking up their
brakes or haven’t learned to
swerve to avoid an accident.
Many inexperienced riders (and
too many seasoned riders) use
only their rear brake in an emer­gency, resulting in unnecessary
impacts in some cases and
unnecessarily high impact speeds
in other cases. Your rear brake
can only provide about 30% of
your motorcycle’s potential stop­ping power. The front and rear
brakes can and should be used
together to maximize braking
effectiveness.

Your eyesight is equally valuable.
Wearing suitable eye protection
can help keep your vision
unblurred by the wind and save
your eyes from airborne hazards
like bugs, dirt, or pebbles kicked
up by tires.

Experienced motorcyclists learn
to “cover” the front brake lever by
lightly resting a couple of fingers
over the lever when riding in traffic
and near intersections to give
their reaction time a head start.

1-3

Emergency stopping and swerv­ing are techniques that you
should practice and master before
you find yourself in an emergency
situation. The best place to prac­tice such techniques is in a con­trolled environment such as the
Motorcycle Safety Foundation’s
(MSF) rider training courses. The
MSF’s Motorcycle Rider Courses
(fundamental techniques) and
Experienced Rider Courses
(advanced strategies) present
hands-on instruction of the basic
principles of motorcycling and a
variety of accident avoidance
maneuvers. Even a seasoned
motorcyclist can improve his or
her riding skills, and pick up a few
new skills, through these courses.
Some insurance companies even
offer discounts to course gradu­ates.

SPECIAL SITUATIONS REQUIRE SPECIAL CARE

Of course, there are some times
when full-force braking is not the
correct technique. When the road
surface is wet, loose, or rough,
you should brake with care. When
you’re leaned over in a corner,
avoid braking. Straighten up
before braking. Better yet, slow
down before entering a corner.

In these situations, the traction
available between your tires and
the road surface is limited. Over­braking when traction is limited
will cause your tires to skid, possi­bly resulting in loss of directional
control or causing you and your
motorcycle to fall over.

1-4

KNOW YOUR LIMITS

Always ride within the boundaries
of your own skills. Knowing these
limits and staying within them will
help you avoid accidents.

A major cause of accidents involv­ing only a motorcycle (and no
cars) is going too fast through a
turn. Before entering a turn, select
an appropriately low cornering
speed.

Even on straight roads, ride at a
speed that is appropriate for the
traffic, visibility and road condi­tions, your motorcycle, and your
experience.

Riding a motorcycle safely
requires that your mental and
physical skills are fully part of the
experience. You should not
attempt to operate a motor vehi­cle, especially one with two
wheels, if you are tired or under
the influence of alcohol or other
drugs. Alcohol, illegal drugs, and
even some prescription and over­the-counter drugs can cause
drowsiness, loss of coordination,
loss of balance, and especially
the loss of good judgment. If you
are tired or under the influence of
alcohol or other drugs, PLEASE
DO NOT RIDE your motorcycle.

BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS

Riding on bad weather days,
especially wet ones, requires
extra caution. Braking distances
increase on a rainy day. Stay off
the painted surface marks, man­hole covers, and greasy appear­ing areas, as they can be
especially slippery. Use extra cau­tion at railway crossings and on
metal gratings and bridges. When
it starts to rain, any oil or grease
on the road rises to the surface of
the water. Pull over and wait a few
minutes until this oil film is
washed away before riding.
Whenever in doubt about road
conditions, slow down!

1-5

PRACTICE AWAY FROM TRAFFIC

Your riding skill and your mechan­ical knowledge form the founda­tion for safe riding practices. We
suggest that you practice riding
your motorcycle in a nontraffic sit­uation until you are thoroughly
familiar with your machine and its
controls. Again, consider taking
one of the MSF’s Rider Courses.
Even experts will be pleased with
the caliber of the information pre­sented in these courses. As the
MSF says: “The more you know,
the better it gets!”

INSPECTION BEFORE RIDING

Review the instructions in the
INSPECTION BEFORE RIDING
section of this manual. Perform an
entire pre-ride inspection before
you head out on the road. Spend­ing a few minutes preparing your
machine for a ride can help pre­vent accidents due to mechanical
failure or costly, inconvenient
breakdowns far from home.

CARRYING A PASSENGER

Carrying a passenger, when done
correctly, is a great way to share
the joy of motorcycling. You will
have to alter your riding style
somewhat since the extra weight
of a passenger will affect handling
and braking. You may also need
to adjust tire pressures and sus­pension; please refer to the Tire
Pressure and Loading section
and the Suspension section for
more details.

A passenger needs the same pro­tection that you do, including a
helmet and proper clothing. The
passenger should not wear long
shoe laces or loose pants that
could get caught in the wheel or
the chain. Passengers must be
tall enough that their feet reach
the footrests.

ACCESSORIES AND LOADING

The accessories you use with your
motorcycle and the manner in
which you load your gear onto the
bike might create hazards. Aerody­namics, handling, balance, and
cornering clearance can suffer,
and the suspension and tires can
be overloaded. Read the ACCES­SORY USE AND MOTORCYCLE
LOADING section.

1-6

MOTORCYCLE SAFETY FOUNDATION’S “RIDING TIPS AND PRACTICE GUIDE” HANDBOOK (FOR OWNERS IN USA)

This special handbook, supplied
with your owner’s manual, con­tains a variety of safety tips, help­ful hints, and practice exercises.
This manual can increase your
riding enjoyment and safety. You
should read it thoroughly.

BE STREET SMART

Always heed speed limits, local
laws, and the basic rules of the
road. Set a good example for oth­ers by demonstrating a courteous
attitude and a responsible riding
style.

LABELS

Read and follow all the labels on
the motorcycle. Make sure you
understand all of the labels. Do
not remove any labels from the
motorcycle.

CONCLUSION

Traffic, road and weather condi­tions vary. Other motorist’s
actions are unpredictable. Your
motorcycle’s condition can
change. These factors can best
be dealt with by giving every ride
your full attention.

Circumstances beyond your con­trol could lead to an accident. You
need to prepare for the unex­pected by wearing a helmet and
other protective gear, and learn­ing emergency braking and
swerving techniques to minimize
the damage to you and your
machine.

The best way to learn basic riding
skills and evasive maneuvers or
refresh your own riding skills is to
take one of the courses offered by
the Motorcycle Safety Foundation.
Your authorized Suzuki dealer
can help you locate the funda­mental or advanced riding skills
course nearest you, or owners in
the USA can call toll-free 1-800­446-9227.

Good riding on your new Suzuki!

1-7

FUEL, OIL AND COOLANT

RECOMMENDATIONS

FUEL .................................................................................................................... 2-2

ENGINE OIL ......................................................................................................... 2-4

GEAR OIL ............................................................................................................ 2-5

ENGINE COOLANT SOLUTION ......................................................................... 2-6

2

2-1

FUEL, OIL AND

or

COOLANT
RECOMMENDATIONS

FUEL

Your motorcycle requires regular
unleaded gasoline with a mini­mum pump octane rating of 87
((R+M)/2 method). In some areas,
the only fuels that are available
are oxygenated fuels.

Oxygenated fuels which meet the
minimum octane requirement and
the requirements described below
may be used in your motorcycle
without jeopardizing the New
Vehicle Limited Warranty or the
Emission Control System War­ranty.

NOTE: Oxygenated fuels are
fuels which contain oxygen-carry­ing additives such as alcohol.

NOTE:

• If the engine develops some
trouble like lack of acceleration
or insufficient power, the cause
may be due to the fuel the
motorcycle uses. In such case,
try changing to a different gas
station. If the situation is not
improved by changing, consult
your Suzuki dealer.

• If pinking or knocking is experi­enced, substitute higher
octane grade gasoline or
another brand, because there
are differences between
brands.

Gasoline/Ethanol Blends

Blends of unleaded gasoline and
ethanol (grain alcohol), also
known as GASOHOL, are com­mercially available in some areas.
Blends of this type may be used in
your motorcycle if they are no
more than 10% ethanol. Make
sure this gasoline-ethanol blend
has octane ratings no lower than
those recommended for gasoline.

Use the recommended gasoline.

2-2

Fuel Pump Labeling

In some states, pumps that dis­pense oxygenated fuels are
required to be labeled for the type
and percentage of oxygenate, and
whether important additives are
present. Such labels may provide
enough information for you to
determine if a particular blend of
fuel meets the requirements listed
above. In other states, pumps
may not be clearly labeled as to
the content or type of oxygenate
and additives. If you are not sure
that the fuel you intend to use
meets these requirements, check
with the service station operator
or the fuel supplier.

NOTE:

• To help minimize air pollution,
Suzuki recommends that you
use oxygenated fuels.

• Be sure that any oxygenated
fuel you use has octane rat­ings of at least 87 pump
octane ((R+M)/2 method).

• If you are not satisfied with the
drivability of your motorcycle
when you are using an oxy­genated fuel, or if engine ping­ing is experienced, substitute
another brand as there are dif­ferences between brands.

NOTICE

Spilled gasoline containing
alcohol can damage the
painted surfaces of your
motorcycle.

Be careful not to spill any fuel
when filling the fuel tank. Wipe
spilled gasoline up immedi­ately.

2-3

ENGINE OIL

ENGINE OIL

TEMP.

Suzuki recommends the use of
SUZUKI PERFORMANCE 4
MOTOR OIL or equivalent engine
oil. If SUZUKI PERFORMANCE 4
MOTOR OIL is not available,
select a proper engine oil accord­ing to the following guideline.
Oil quality is a major contributor to
your engine’s performance and
life. Always select good quality
engine oil. Use oil with an API
(American Petroleum Institute)
classification of SG, SH, SJ, SL,
SM or SN with a JASO classifica­tion of MA.

SAE Engine Oil Viscosity

Suzuki recommends the use of
SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available,
select an alternative according to
the following chart.

* USE ONLY SG, SH, SJ or SL.

SAE API JASO

10W-40

SG, SH, SJ, SL,

SM or SN

API: American Petroleum Institute
JASO: Japanese Automobile
Standards Organization

NOTE: SUZUKI highly recom­mends the use of ECSTAR brand
engine oil. ECSTAR has been
specially formulated for your
SUZUKI product and contributes
to the desired motorcycle perfor­mance and ideal riding experi­ence.

MA

JASO T903

The JASO T903 standard is an
index to select engine oils for 4­stroke motorcycle and ATV
engines. Motorcycle and ATV
engines lubricate clutch and
transmission gears with engine
oil. JASO T903 specifies perfor­mance requirements for motorcy­cle and ATV clutches and
transmissions.

There are two classes, MA and
MB. The oil container shows the
classification as follows.

1 Code number of oil sales company
2 Oil classification

2-4

Energy Conserving

E

N

E

R

G

Y

C

O

N

S

E

R

V

I

N

G

A

P

I

S

E

R

V

I

C

E

S

J

SAE

10W-40

R

E

S

O

U

R

C

E

C

O

N

S

E

R

V

I

N

G

A

P

I

S

E

R

V

I

C

E

S

N

SAE

10W-40

Suzuki does not recommend the
use of “ENERGY CONSERVING”
or “RESOURCE CONSERVING”
oils. Some engine oils which have
an API classification of SH, SJ,
SL, SM or SN have an “ENERGY
CONSERVING” or “RESOURCE
CONSERVING” indication in the
API classification donut mark.
These oils can affect engine life
and clutch performance.

API SG, SH, SJ, SL, SM or SN

V

R

I

C

E

E

S

I

S

P

SAE

10W-40

J

A

Recommended

GEAR OIL

Use an SAE90 hypoid gear oil
which is rated GL-5 under the API
classification system. If you oper­ate the motorcycle where ambient
temperature is below 0°C (32°F),
use SAE80 hypoid gear oil.

API SH, SJ, SL or SM

Not recommended

API SN

2-5

ENGINE COOLANT SOLUTION

Use “SUZUKI SUPER LONG
LIFE COOLANT” or “SUZUKI
LONG LIFE COOLANT”. If
“SUZUKI SUPER LONG LIFE
COOLANT” and “SUZUKI LONG
LIFE COOLANT” are not avail­able, use a glycol-based anti­freeze compatible with an
aluminum radiator mixed with dis­tilled water only at the ratio of
50:50.

 WARNING

Engine coolant is harmful or
fatal if swallowed or inhaled.
Solution can be poisonous to
animals.

Do not drink antifreeze or cool­ant solution. If swallowed, do
not induce vomiting. Immedi­ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Keep out of the
reach of children and animals.

NOTICE

Spilled engine coolant can
damage the painted surfaces of
your motorcycle.

Be careful not to spill any fluid
when filling the radiator. Wipe
spilled engine coolant up
immediately.

NOTE: SUZUKI highly recom­mends the use of ECSTAR brand
coolant. ECSTAR has been spe­cially formulated for your SUZUKI
product and contributes to the
desired motorcycle performance
and ideal riding experience.

2-6

ENGINE COOLANT

Engine coolant performs as a rust
inhibitor and water pump lubricant
as well as an anti-freeze solution.
Therefore engine coolant should
be used at all times even though
the atmospheric temperature in
your area does not go down to the
freezing point.

SUZUKI SUPER LONG LIFE
COOLANT (Blue)

“SUZUKI SUPER LONG LIFE
COOLANT” is pre-mixed to the
proper ratio. Add only “SUZUKI
SUPER LONG LIFE COOLANT”
if coolant level drops. It is not nec­essary to dilute “SUZUKI SUPER
LONG LIFE COOLANT” when
replacing coolant.

SUZUKI LONG LIFE COOLANT
(Green)

Water for Mixing

Use distilled water only. Water
other than distilled water can cor­rode and clog the aluminum radia­tor.

Required amount of engine cool­ant/water solution capacity (total):
1750 ml (1.8 US qt)

Engine coolant 875 ml (0.9 US qt)

Water 875 ml (0.9 US qt)

NOTE: This 50% mixture will
protect the cooling system from
freezing at temperatures above
–31°C (–24°F). If the motorcycle
is to be exposed to temperature
below –31°C (–24°F), this mix­ing ratio should be increased up
to 55% (–40°C/–40°F) or 60%
(–55°C/–67°F) coolant. The mix­ing ratio should not exceed 60%
coolant.

2-7

CONTROLS, EQUIPMENT AND

ADJUSTMENTS

LOCATION OF PARTS ....................................................................................... 3-2

KEY ...................................................................................................................... 3-5

IGNITION SWITCH .............................................................................................. 3-5

INSTRUMENT PANEL ......................................................................................... 3-8

LEFT HANDLEBAR ........................................................................................... 3-14

RIGHT HANDLEBAR ........................................................................................3-16

FUEL TANK CAP .............................................................................................. 3-18

GEARSHIFT LEVER .......................................................................................... 3-19

REAR BRAKE PEDAL ...................................................................................... 3-19

HELMET HOLDER ............................................................................................ 3-20

SIDE STAND ...................................................................................................... 3-20

SUSPENSION ADJUSTMENT .......................................................................... 3-21

3

3-1

CONTROLS, EQUIPMENT AND ADJUSTMENTS

LOCATION OF PARTS

1 Clutch lever
2 Left handlebar switches
3 Instrument panel
4 Front brake fluid reservoir
5 Right handlebar switches
6 Throttle grip
7 Front brake lever
8 Fuel tank cap

3-2

VL800

9 Spark plugs
0 Battery and main fuse
A To ols
B Helmet holder
C Gearshift lever
D Footrests
E Engine coolant reservoir
F Side stand
G Fuses
H Passenger footrests

VL800T

3-3

VL800

I Air cleaner
J Ignition switch
K Engine oil filler cap
L Engine oil inspection window
M Engine oil drain plug
N Engine oil filter
O Rear brake light switch
P Rear brake pedal

VL800T

3-4

KEY

IGNITION SWITCH

Two keys come with this motorcy­cle. Keep the spare key in a safe
place.

The ignition switch has 4 posi­tions.

“OFF” position

All electrical circuits are cut off.
The engine will not start. The key
can be removed.

“ON” position

The ignition circuit is completed
and the engine can be started.
The headlight, front turn signal
light and taillight will automatically
turn on. The key cannot be
removed in this position.

NOTE: Start the engine promptly
after turning the key to the “ON”
position, or the battery will lose
power due to consumption by the
headlight and taillight.

3-5

“LOCK” position

All electrical circuits are off. The
key can be removed and the
steering will be locked. Turn the
steering all the way to the left and
push down the key and turn it to
the “LOCK” position.

NOTE:

• Move the handlebar to the
right and left, to make sure that
the steering has been locked
securely.

• When it cannot be locked eas­ily, turn the key to the “LOCK”
position, moving the handlebar
slightly to the right.

“P” (PARKING) position

The taillight will come on to
increase visibility for temporary
road side parking at night. The
key can be removed and the
steering will be locked.

 WARNING

Turning the ignition switch to
the “P” (PARKING) or “LOCK”
position while the motorcycle
is moving can be hazardous.
Moving the motorcycle while
the steering is locked can be
hazardous. You could lose your
balance and fall, or you could
drop the motorcycle.

Stop the motorcycle and place
it on the side stand before lock­ing the steering. Never attempt
to move the motorcycle when
the steering is locked.

 WARNING

If the motorcycle falls down
due to a slip or collision, unex­pected damage to the motorcy­cle could cause the engine to
keep running, which could
result in a fire, or could result
in injury from moving parts
such as the rear wheel.

If the motorcycle falls down,
turn the ignition switch off
immediately. Ask your autho­rized Suzuki dealer to inspect
the motorcycle for unseen
damage.

3-6

The key hole can be covered by
turning the lid.

Align the lid hole position with the
key hole position when inserting
the key.

3-7

INSTRUMENT PANEL

FI

EF

AB

GEAR

The oil pressure indicator light 3,
engine coolant temperature indi­cator light 5, fuel injection sys­tem indicator light 6, LCD and
meter needle work as follows to
confirm their function when the
ignition switch is turned to the
“ON” position.

• The oil pressure indicator light
3, engine coolant tempera­ture indicator light 5 and fuel
injection system indicator light
6 come on for 2 seconds.

• The meter needle moves to
the full scale position and
returns to the home position.

• All LCD segments appear/dis­appear and then show the nor­mal display.

SPEEDOMETER 1

The speedometer indicates the
road speed in kilometers per hour
and miles per hour.

If the speedometer needle does
not point to zero, follow the proce­dure below to reset the speedom­eter.

1. Press and hold the button 9

and turn on the ignition switch.

2. Hold the button 9 for 3 sec-

onds.

NOTE: The reset procedure, from
step 1 to step 2, should be per­formed within 10 seconds.

TURN SIGNAL INDICATOR
LIGHT “” 2

When the turn signals are being
operated either to the right or to
the left, the indicator light will blink
intermittently.

NOTE: If a turn signal light is not
operating properly due to bulb fila­ment or circuit failure, the indica­tor light blinks more quickly to
notify the rider of the existence of
a problem.

3-8

OIL PRESSURE INDICATOR
LIGHT “” 3

This indicator light comes on
when the engine oil pressure is
below the normal operating
range.

NEUTRAL INDICATOR LIGHT
“N” 4

The green light will come on when
the transmission is in neutral. The
light will go out when you shift into
any gear other than neutral.

NOTICE

After starting the engine, open­ing the throttle or running the
motorcycle with the oil pres­sure indicator light turned on
may adversely affect the
engine.

Make sure that the oil pressure
indicator light has turned off
before operating the throttle or
running the motorcycle.

NOTICE

Riding the motorcycle with the
oil pressure indicator light lit
can damage the engine and
transmission.

If the oil pressure indicator
light comes on, indicating low
oil pressure, stop the engine
immediately. Check the oil level
and add oil if necessary. If
there is a proper amount of oil
and the light still does not go
out, have your authorized
Suzuki dealer or a qualified
mechanic inspect your motor­cycle.

ENGINE COOLANT
TEMPERATURE INDICATOR
LIGHT “” 5

This indicator light comes on
when the coolant temperature
indicates more than 120°C
(248°F). When the engine coolant
temperature indicator light comes
on, stop the engine and check the
coolant level after the engine
cools.

NOTICE

Riding the motorcycle with the
engine coolant temperature
indicator light lit can cause
serious engine damage due to
overheating.

If the engine coolant tempera­ture indicator light comes on,
stop the engine to let it cool.
Do not run the engine until the
engine coolant temperature
indicator light goes off.

3-9

FUEL INJECTION SYSTEM

FI

EF

AB

GEAR

INDICATOR LIGHT “FI” 6

If the fuel injection system fails,
the fuel injection system indicator
light 6 comes on and the display
indicates “FI” at the clock display
in the following two modes;

A. The display 7 indicates “FI”

intermittently, and the fuel
injection system indicator light
6 comes on and remains lit.

B. The display 7 indicates “FI”

continuously and the fuel injec­tion system indicator light 6
blinks while cranking the
engine.

The engine may continue to run in
mode A, but the engine will not
run in mode B.

NOTICE

The fuel injection indicator
light comes on to indicate a
problem with the fuel injection
system.

If the display indicates “FI” and
the fuel injection system indi­cator light comes on, have your
authorized Suzuki dealer or a
qualified mechanic inspect the
fuel injection system as soon
as possible.

NOTE: If the display indicates “FI”
continuously and the fuel injection
system indicator light blinks, the
engine will not start.

When the display indicates
“CHEC”, check the following
items;

• Make sure that the engine stop

switch is in the “” position.

• Make sure that the transmis­sion is in neutral or the side
stand is fully up.

If the display still indicates
“CHEC” after checking the above
items, inspect the ignition fuse
and the connection of the lead
wire couplers.

3-10

COMBINATION SYSTEM

A B

GEAR

GEAR

A

GEAR

B

GEAR

GEAR

Odometer

Tr ip m e t er A

Trip meter B

Instrument panel light brightness

(VL800T)

DISPLAY 7

The display has six functions,
clock, odometer, two trip meters,
instrument panel light brightness
(VL800T) and gear position.
When the ignition switch is turned
to the “ON” position, the display
indicates the test pattern shown
below for two seconds.

To change the display, push the
button 8. The display changes in
the order below.

 WARNING

Changing the display while rid­ing can be hazardous. Remov­ing a hand from the handlebars
can reduce your ability to con­trol the motorcycle.

Never change the display while
riding. Keep both hands on the
handlebars.

3-11

Clock

FI

EF

AB

GEAR

The clock has a 12-hour display.
Follow the procedure below to
adjust the clock.

1. Push the buttons, 8 and 9,

simultaneously for 2 seconds
until the hour display blinks.

2. Adjust the hour display by

pushing the button 9.

NOTE: When the button 9 is held
in the display advances continu­ously.

3. Push the button 8 to highlight

the minute display.

4. Adjust the minute display by

pushing the button 9.

5. Push the button 8 to return to

the clock mode.

Odometer

The odometer registers the total
distance that the motorcycle has
been ridden. The odometer
ranges from 0 to 999999.

NOTE: The odometer display
locks at 999999 when the total
distance exceeds 999999.

Trip Meters

The two trip meters are resettable
odometers. They can register two
kinds of distances at the same
time. For instance, trip meter A
can register the trip distance and
trip meter B can register the dis­tance between fuel stops.

To reset a trip meter to zero, push
the button 9 for 2 seconds while
the display indicates the trip meter
A, or B, you want to reset.

NOTE: When the trip meter
exceeds 9999.9, the trip meter will
return to 0.0 and start counting
again.

Instrument Panel Light
Brightness (VL800T)

Pushing the button 9 will change
the instrument panel light bright­ness in 6 steps. The brightness
indicator indicates brightness
from “” (min) to “



(max).

”

3-12

Gear Position Indicator

The gear position indicator indi­cates gear position. This indica­tor displays “0” when the
transmission is in neutral.

NOTE: When the display indi­cates “CHEC”, the gear position
indicator does not indicate a num­ber but indicates “–”.

FUEL LEVEL INDICATOR “”

0

The fuel level indicator indicates
the amount of fuel remaining in
the fuel tank. The fuel level indica­tor displays all 5 segments when
the fuel tank is full. The segment
comes on when the fuel level
drops below 3.5 L (3.7 US qt).
The segment blink when the fuel
drops below 1.5 L (1.6 US qt).

HIGH BEAM INDICATOR LIGHT
“” A

This blue indicator light will come
on when the headlight high beam
is turned on.

Fuel tank

Segment

Approxi-

mately

1.5 L

Blink

Approxi-

mately

3.5 L

Full

NOTE: The fuel level indicator will
not indicate correctly when the
motorcycle is placed on the side
stand. Turn the ignition switch to
the “ON” position when the motor­cycle is held upright.

3-13

LEFT HANDLEBAR

Clutch Lever 1

The clutch lever is used for disen­gaging the drive to the rear wheel
when starting the engine or shift­ing transmission gears. Squeez­ing the lever disengages the
clutch.

Headlight Flasher Switch 2

Press the switch to flash the
headlight.

NOTICE

Holding the dimmer switch
between the “” and “”
position will light both the high
and low headlight beam. This
improper operation can dam­age the motorcycle’s headlight.

Use the dimmer switch to
select only the “” or “”
position.

NOTICE

Sticking tape or placing
objects in front of the headlight
can obstruct headlight heat
radiation. This can result in
headlight damage.

Dimmer Switch 3
“” position

The headlight low beam turns on.

“” position

The headlight high beam turns
on. The high beam indicator light
also comes on.

Do not stick tape on the head­light or place objects in front of
the headlight.

NOTICE

Do not put objects in front of
the headlight or taillight when
they are on, and do not cover
with clothes when the motorcy­cle is stopped.

This may cause melting of the
lens or damage to the object by
the heat from the lens.

3-14

Turn Signal light Switch “”

4

Moving the switch to the “”
position will flash the left turn sig­nals. Moving the switch to the “”
position will flash the right turn
signals. The indicator light will
also flash intermittently. To cancel
turn signal operation, push the
switch in.

 WARNING

Failure to use the turn signals,
and failure to turn off the turn
signals can be hazardous.
Other drivers may misjudge
your course and this may
result in an accident.

Always use the turn signals
when you intend to change
lanes or make a turn. Be sure
to turn off the turn signals after
completing the turn or lane
change.

Horn Switch “” 5

Press the switch to sound the
horn.

Hazard Warning Switch “” 6

All four turn signal lights and indi­cators will flash simultaneously
when the switch is turned on with
the ignition switch in the “ON” or
“P” position. Use the hazard
warning lights to warn other traffic
during emergency parking or
when your vehicle could other­wise become a traffic hazard.

3-15

RIGHT HANDLEBAR

Front Brake Lever Adjustment

Engine Stop Switch 1
“” position

The ignition circuit is off. The
engine cannot start or run.

“” position

The ignition circuit is on and the
engine can run.

NOTICE

Changing the engine stop
switch from  to  or from



to  to  while riding may
damage to the engine or the
catalytic converter (if equipped).

Do not use the engine stop
switch except for an emer­gency.

Front Brake Lever 2

Apply the front brake by squeez­ing the front brake lever toward
the grip. The brake light will come
on when the lever is squeezed.

The distance between the throttle
grip and the front brake lever is
adjustable to 5 positions. To
change the position, push the
brake lever forward and turn the
adjuster to the desired position.
Be sure the adjuster stops in the
proper position; a projection of the
brake lever holder should fit into
the depression of the adjuster.
This motorcycle is delivered from
the factory with its adjuster set on
position 3.

 WARNING

Adjusting the front brake lever
position while riding can be
hazardous. Removing a hand
from the handlebars can
reduce your ability to control
the motorcycle.

Never adjust the front brake
lever position while riding.
Keep both hands on the han­dlebars.

3-16

Electric Starter Switch “” 3

Use this switch to operate the
starter motor. With the ignition
switch in the “ON” position, the
engine stop switch in the “”
position, and the transmission in
neutral, pull in the clutch lever and
push the electric starter switch to
start the engine.

NOTE: This motorcycle has a
starter interlock system for the
ignition and starter circuit. The
engine can only be started if:

• The transmission is in neutral
and the clutch is disengaged,
or

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

NOTE: The headlight will go off
when the electric starter switch is
pushed.

NOTICE

If the neutral indicator light and
the gear position indicator are
not giving proper indications,
starting the engine can cause
serious engine damage.

Before starting the engine,
make sure of the followings:

• When the neutral indicator
light comes on, the gear
position indicator should
indicate “0” (Neutral).

• When the neutral indicator
light goes off, the gear posi­tion indicator should indicate
either “1”, “2”, “3”, “4” or
“5”.

• If the neutral indicator light
and the gear position indica­tor are not working properly,
consult your Suzuki dealer.

NOTICE

Engaging the starter motor for
more than five seconds at a
time can damage the starter
motor and wiring harness from
overheating.

Do not engage the starter
motor for more than five sec­onds at a time. If the engine
does not start after several
attempts, check the fuel supply
and ignition system. Refer to
the TROUBLESHOOTING sec­tion in this manual.

3-17

Throttle Grip 4

Engine speed is controlled by the
position of the throttle grip. Turn it
toward you to increase engine
speed. Turn it away from you to
decrease engine speed.

FUEL TANK CAP

1 Fuel level
2 Filler neck

To open the fuel tank cap, insert
the ignition key into the lock and
turn it clockwise. With the key
inserted, lift the cap up with key.
To close the fuel tank cap, push
the cap down firmly with the key in
the cap lock.

Use fresh gasoline when filling up
the fuel tank. Do not use bad gas­oline which is contaminated with
dirt, dust, water or other liquid. Be
careful that dirt, dust or water do
not enter the fuel tank when refu­eling.

Fuel tank capacity: 15.5L (4.1US
gal)

 WARNING

If you overfill the fuel tank, fuel
may overflow when it expands
due to engine heat or heating
by the sun. Fuel that overflows
can catch fire.

Stop adding fuel when the fuel
level reaches the bottom of the
filler neck.

 WARNING

Failure to follow safety precau­tions when refueling could
result in a fire or cause you to
breathe toxic fumes.

Refuel in a well ventilated area.
Make sure the engine is off and
avoid spilling fuel on a hot
engine. Do not smoke, and
make sure there are no open
flames or sparks in the area.
Avoid breathing gasoline
vapors. Keep children and pets
away when you refuel the
motorcycle.

3-18

GEARSHIFT LEVER

REAR BRAKE PEDAL

This motorcycle has 5-speed
transmission which operates as
shown. To shift properly, squeeze
the clutch lever and close the
throttle at the same time you
operate the gearshift lever. Lift the
front end of the gear shift lever or
depress the rear end of the gear­shift lever to upshift. Depress the
front end of the gearshift lever to
downshift. Neutral is located
between 1st and 2nd gear. When
neutral is desired, depress or lift
the lever halfway between 1st and
2nd gear.

NOTE: When the transmission is
in neutral, the green indicator light
on the instrument panel will be lit.
However, even though the light is
lit, cautiously and slowly release
the clutch lever to make sure that
the transmission is positively in
neutral.

Pressing the rear brake pedal will
apply the rear brake. The brake
light will come on when the rear
brake is operated.

3-19

HELMET HOLDER

SIDE STAND

The helmet holder is located on
the left side below the rear seat.
Insert the ignition key into the lock
and turn it clockwise to open the
latch. Hook your helmet fastener
ring to the latch and turn the key
back to lock the holder.

 WARNING

Riding with a helmet fastened
to the helmet holder can inter­fere with rider control.

Never carry a helmet fastened
to the helmet holder. Fix the
helmet securely atop the seat if
you must carry it.

The motorcycle has a side stand.
To place the motorcycle on the
side stand, place your right foot
on the end of the side stand and
push down firmly until the stand
pivots fully through its arc and
comes to rest against it stop.

An interlock system is provided to
cut off the ignition circuit when the
side stand is down and the trans­mission is in any gear other than
neutral.

The side stand/ignition interlock
system works as follows:

• If the side stand is down and
the transmission is in gear, the
engine cannot be started.

• If the engine is running and the
transmission is shifted into
gear with the side stand down,
the engine will stop running.

• If the engine is running and the
side stand is put down with the
transmission in gear, the
engine will stop running.

3-20

 WARNING

Riding with the side stand
incompletely retracted can
result in an accident when you
turn left.

Check operation of the side
stand/ignition interlock sys­tem before riding. Always
retract the side stand com­pletely before starting off.

SUSPENSION ADJUSTMENT

REAR SUSPENSION LABEL

 WARNING

This unit contains high-pres­sure nitrogen gas.
Mishandling can cause explo­sion.

NOTICE

If you do not take proper pre­cautions when parking, the
motorcycle can fall over.

Park the motorcycle on firm,
level ground whenever possi­ble. If you must park on an
incline, aim the front of the
motorcycle uphill and put the
transmission into 1st gear to
reduce the possibility of rolling
off the side stand.

• Keep away from fire and heat.

• Read owner’s manual for
more information.

NOTE: Ask your Suzuki dealer to
dispose of the rear suspension
unit.

3-21

REAR SUSPENSION
Spring Pre-load Adjustment

The rear suspension spring pre­load is adjustable to compensate
for rider, load, riding style and
road conditions. The adjustment
can be performed in seven posi­tions. To change the spring pre­load setting, follow the procedure
below.

1. Place the motorcycle on the
side stand.

4. Unhook the hooks and remove
the cover.

2. Insert the ignition key into the
lock and turn it counterclock­wise. Unhook the hooks and
remove the left frame cover.

3. Pull the hook to open the box
lid.

5. Loosen the bolts and remove
the tool box.

3-22

6. Twist the spring tension ring to
the desired position with an
adjuster. Position 1 provides
the softest spring tension and
position 7 provides the stiffest.
This motorcycles is delivered
from the factory with its
adjuster set on position 4.

NOTE: Use a hook type spring
adjuster or Suzuki spring adjuster,
Part number 09822-00003 to
adjust the rear suspension spring.
The Suzuki spring adjuster is
available from your Suzuki dealer.

NOTE: If it is hard to adjust the
spring pre-road, remove the bolts
and move the battery box.

3-23

BREAK-IN AND INSPECTION

BEFORE RIDING

BREAK-IN ............................................................................................................ 4-2

INSPECTION BEFORE RIDING .......................................................................... 4-3

4

4-1

BREAK-IN AND
INSPECTION BEFORE
RIDING

BREAK-IN

The first 800 km (500 miles) is the
most important in the life of your
motorcycle. Proper operation
during this break-in period will
help assure maximum life and
performance from your new
motorcycle. The following guide­lines explain proper break-in pro­cedures.

Maximum Throttle Opening
Recommendation

The table below shows the maxi­mum throttle opening recommen­dation during the break-in period.

Up to 800 km

(500 miles)

Up to 1600 km

(1000 miles)

Vary the Engine Speed

Vary the engine speed during the
break-in period. This allows the
parts to “load” (aiding the mating
process) and then “unload”
(allowing the parts to cool).
Although it is essential to place
some stress on the engine com­ponents during break-in, you must
be careful not to load the engine
too much.

Less than

1/2 throttle

Less than

3/4 throttle

Breaking in the New Tires

New tires need proper break-in to
assure maximum performance,
just as the engine does. Wear in
the tread surface by gradually
increasing your cornering lean
angles over the first 160 km (100
miles) before attempting maxi­mum performance. Avoid hard
acceleration, hard cornering, and
hard braking for the first 160 km
(100 miles).

 WARNING

Failure to perform break-in of
the tires could cause tire slip
and loss of control.

Use extra care when riding on
new tires. Perform proper
break-in of the tires as
described in this section and
avoid hard acceleration, hard
cornering, and hard braking for
the first 160 km (100 miles).

4-2

Observe Your Initial and Most
Critical Service

The initial service (1000 km main­tenance) is the most important
service your motorcycle will
receive. During break-in opera­tion, all of the engine components
will have mated together and
seated. Maintenance required as
part of the initial service includes
correction of all adjustments,
tightening of all fasteners and
replacement of dirty oil. Timely
performance of this service will
help make sure you get the best
service life and performance from
the engine.

NOTE: The 1000 km (600 miles)
service should be performed as
outlined in the Maintenance
Schedule section of this Owner’s
Manual. Pay particular attention to
the caution and warning mes­sages in MAINTENANCE
SCHEDULE section.

INSPECTION BEFORE RIDING

 WARNING

Failure to inspect your motor­cycle before riding and to prop­erly maintain your motorcycle
increases the chances of an
accident or equipment dam­age.

Always inspect your motorcy­cle each time you use it to
make sure it is in safe operat­ing condition. Refer to the
INSPECTION AND MAINTE­NANCE section in this owner’s
manual.

 WARNING

If you operate this motorcycle
with improper tires or improper
or uneven tire pressure, you
may lose control of the motor­cycle. This will increase your
risk of an accident.

Always use tires of the size and
type specified in this owner’s
manual. Always maintain
proper tire pressure as
described in the INSPECTION
AND MAINTENANCE section.

4-3

Check the condition of the motor­cycle to help make sure that you
do not have mechanical problems
or get stranded somewhere when
you ride. Before riding the motor­cycle, be sure to check the follow­ing items. Be sure your
motorcycle is in good condition for
the personal safety of the rider,
passenger and protection of the
motorcycle.

WARNING

Checking maintenance items
when the engine is running can
be hazardous. You could be
severely injured if your hands
or clothing get caught in mov­ing engine parts.

Shut the engine off when per­forming maintenance checks,
except when checking the
lights, engine stop switch, and
throttle.

WHAT TO

CHECK

Steering • Smoothness

Brakes
( 3-16,
3-19, 7-29)

Tires
( 7-35)

CHECK FOR:

• No restriction of movement

• No play or looseness

• Proper pedal and lever
operation

• Correct fluid level

• No fluid leakage

• No “sponginess”

• Proper pedal and lever play

• Brake pad wear

• Brake shoe wear

• Proper pressure

• Enough tread depth

• No cracks, rips, or other
damage

Fuel tank
( 3-18)

Lighting
( 3-5,
3-8, 3-14)

Engine stop
switch
( 3-16)

Horn
( 3-15)

Engine oil
( 7-17)

Cooling
system
( 7-26)

Gear oil
( 7-28)

Throttle
( 3-17,
7-22)

Gearshift
lever
( 3-19)

Clutch
( 7-25)

Side stand/
ignition
interlock
system
( 7-38)

General
condition

Tank cap locked securely

Operation of all lights and
indicators

Proper operation

Correct function

Correct level

• Proper coolant level

• No leaks or damage

Correct level

• Proper play

• Smooth response

• Quick return to idle position

• No damage

• Smooth operation

• Smooth and progressive
action

• Proper lever play

Proper operation

• Bolts and nuts tightness

• No rattle from any parts of
machine with the engine
running

• No visible evidence of
damage

4-4

RIDING TIPS

STARTING THE ENGINE .................................................................................... 5-2

STARTING OFF AND SHIFTING ........................................................................ 5-4

USING THE TRANSMISSION ............................................................................. 5-5

RIDING ON HILLS ............................................................................................... 5-6

STOPPING AND PARKING ................................................................................ 5-6

CARRYING A PASSENGER ............................................................................... 5-8

5

5-1

RIDING TIPS

STARTING THE ENGINE

Before attempting to start the
engine, make sure:

• The transmission is in neutral.

• The engine stop switch is in

the “” position.

NOTICE

If the neutral indicator light and
the gear position indicator are
not giving proper indications,
starting the engine can cause
serious engine damage.

NOTE: This motorcycle has inter­lock system for the ignition circuit
and the starter circuit. The engine
can only be started if:

• The transmission is in neutral
and the clutch is disengaged,
or

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

NOTE: The fuel supply system
stops the engine when the motor­cycle is overturned. Turn off the
ignition switch before restarting
the engine.

Before starting the engine,
make sure of the followings:

• When the neutral indicator
light comes on, the gear
position indicator should
indicate “0” (Neutral).

• When the neutral indicator
light goes off, the gear posi­tion indicator should indicate
either “1”, “2”, “3”, “4” or
“5”.

• If the neutral indicator light
and the gear position indica­tor are not working properly,
consult your Suzuki dealer.

When the Engine is Cold:

1. Close the throttle completely.

2. Squeeze the clutch lever and
push the electric starter
switch.

When the Engine is Warm:

Close the throttle completely and
push the electric starter switch.

When a Warm Engine is Hard to
Start:

Open the throttle 1/8 to 1/4 turn
and push the electric starter
switch.

5-2

 WARNING

Exhaust gas contains carbon
monoxide, a dangerous gas
that is difficult to detect
because it is colorless and
odorless. Breathing carbon
monoxide can cause death or
severe injury.

NOTICE

Running the engine too long
without riding may cause the
engine to overheat. Overheat­ing can result in damage to
internal engine components
and discoloration of exhaust
pipes.

Never start the engine or let it
run indoors or where there is
little or no ventilation.

NOTICE

After starting the engine, open­ing the throttle or running the
motorcycle with the oil pres­sure indicator light turned on
may adversely affect the
engine.
Make sure that the oil pressure
indicator light has turned off
before operating the throttle or
running the motorcycle.

Shut the engine off if you can­not begin your ride promptly.

5-3

STARTING OFF AND SHIFTING

 WARNING

Riding at excessive speeds
increases your chances of los­ing control of the motorcycle,
which can result in an acci­dent.

 WARNING

Sudden side winds, which can
occur when being passed by
larger vehicles, at tunnel exits
or in hilly areas, can cause you
to lose control of the motorcy­cle.

Always ride at a speed that is
proper for the terrain, visibility
and operating conditions, and
your skills and experience.

 WARNING

If you remove even one hand or
foot from the motorcycle, you
can reduce your ability to con­trol the motorcycle. This could
cause you to lose your balance
and fall off the motorcycle. If
you remove a foot from a foot­rest, your foot or leg may come
in contact with the rear wheel.
This could injure you or cause
an accident.

Always keep both hands on the
handlebars and both feet on
the footrests of your motorcy­cle during operation.

Reduce your speed and be
alert to the possibility of sud­den side winds.

Make sure that the side stand is in
the fully up position. Squeeze the
clutch lever in and pause momen­tarily. Engage first gear by
depressing the gearshift lever
downward. Turn the throttle grip a
little toward you and at the same
time release the clutch lever gen­tly and smoothly. As the clutch
engages, the motorcycle will start
moving forward. To shift to the
next higher gear, accelerate gen­tly, then close the throttle and
squeeze the clutch lever in simul­taneously. Lift the gearshift lever
upward to select the next gear
and release the clutch lever as
you open the throttle again. Select
higher gears in this manner until
top gear is reached.

NOTE: This motorcycle has a side
stand/ignition interlock system. If
you shift the transmission into
gear when the side stand is down,
the engine will stop running.

5-4

USING THE TRANSMISSION

The transmission is provided to
keep the engine operating
smoothly in its normal operating
speed range. The gear ratios
have been carefully chosen to
meet the characteristics of the
engine. The rider should always
select the most suitable gear for
the prevailing conditions. Never
slip the clutch to control road
speed, but rather downshift to
allow the engine to run within its
normal operational range. The
table below shows the approxi­mate speed range for each gear.

 WARNING

Downshifting when engine
speed is too high can:

• cause the rear wheel to skid
and lose traction due to
increased engine braking,
resulting in an accident; or

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

Reduce speed before down­shifting.

Shifting up schedule

Gear position mph km/h

1st  2nd 12 20

2nd  3rd 19 30

3rd  4th 25 40

4th  Top 3 1 5 0

Shifting down schedule

Gear position mph km/h

Top  4th 19 30

Disengage the clutch when the
motorcycle speed drops below 12
mph (20 km/h).

 WARNING

Downshifting while the motor­cycle is leaned over in a corner
may cause rear wheel skid and
loss of control.

Reduce your speed and down­shift before entering a corner.

NOTICE

Improper gearshift lever opera­tion can damage the transmis­sion.

• Do not rest your foot on the
gearshift lever.

• Do not use force to shift
gears.

5-5

RIDING ON HILLS

• When climbing steep hills, the
motorcycle may begin to slow
down and show lack of power.
At this point you should shift to
a lower gear so that the engine
will again be operating in its
normal power range. Shift rap­idly to prevent the motorcycle
from losing momentum.

• When riding down a steep hill,
the engine may be used for
braking by shifting to a lower
gear.

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

STOPPING AND PARKING

1. Twist the throttle grip away
from yourself to close the
throttle completely.

2. Apply the front and rear brakes
evenly and at the same time.

3. Downshift through the gears
as road speed decreases.

4. Select neutral with the clutch
lever squeezed toward the grip
(disengaged position) when
the motorcycle is almost com­pletely stopped. The neutral
position can be confirmed by
observing the neutral indicator
light.

 WARNING

Inexperienced riders tend to
underutilize the front brake.
This can cause excessive stop­ping distance and lead to a col­lision. Using only the front or
rear brake can cause skidding
and loss of control.

Apply both brakes evenly and
at the same time.

 WARNING

Hard braking while turning may
cause wheel skid and loss of
control.

Brake before you begin to turn.

5-6

 WARNING

Hard braking on wet, loose,
rough, or other slippery sur­faces can cause wheel skid
and loss of control.

Brake lightly and with care on
slippery or irregular surfaces.

 WARNING

Following another vehicle too
closely can lead to collision. As
vehicle speeds increase, stop­ping distance increases pro­gressively.

Always maintain a safe stop­ping distance between you and
the vehicle in front of you.

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

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

7. Turn the handlebars all the
way to the left and lock the
steering for security.

8. Remove the keys.

NOTE: If an optional anti-theft
lock such as a U-shape lock,
brake disk lock or chain is used to
avoid theft, be sure to remove the
anti-theft lock before moving the
motorcycle.

 CAUTION

A hot muffler can cause severe
burns. The muffler will be hot
enough to cause burns for
some time after stopping the
engine.

NOTICE

Holding the motorcycle
stopped with throttle and
clutch lever operation on
inclines can damage the motor­cycle’s clutch.

Use the brakes when stopping
the motorcycle on inclines.

Park the motorcycle where
pedestrians or children are not
likely to touch the muffler.

5-7

CARRYING A PASSENGER

Before you invite someone to be a
passenger on your motorcycle,
you need to be thoroughly familiar
with motorcycle operation. Adjust
tire pressures and suspension
according to the Tire Pressure
and Loading section and the Sus­pension section of this manual.

The passenger should always
hold onto your waist or hips, or
onto the seat strap or grab bar, as
equipped. Ask your passenger
not to make any sudden move­ments. When you lean going
around a corner, the passenger
should lean with you. The passen­ger should always keep his or her
feet on the footrests, even when
you are stopped at a light.

To help prevent burn injuries,
warn your passenger not to con­tact the muffler when mounting or
dismounting your motorcycle.

5-8

ACCESSORY USE AND

MOTORCYCLE LOADING

ACCESSORY USE .............................................................................................. 6-2

ACCESSORY INSTALLATION GUIDELINES ....................................................6-2

LOADING LIMIT .................................................................................................. 6-3

LOADING GUIDELINES ...................................................................................... 6-4

MODIFICATION ................................................................................................... 6-4

6

6-1

ACCESSORY USE AND
MOTORCYCLE
LOADING

ACCESSORY USE

The addition of unsuitable acces­sories can lead to unsafe operat­ing conditions. It is not possible
for Suzuki to test each accessory
on the market or combinations of
all the available accessories; how­ever, your dealer can assist you in
selecting quality accessories and
installing them correctly. Use
extreme caution when selecting
and installing the accessories on
your motorcycle and consult your
Suzuki dealer if you have any
questions.

 WARNING

Improper installation of acces­sories or modification of the
motorcycle may cause
changes in handling which
could lead to an accident.

Never use improper accesso­ries, and make sure that any
accessories that are used are
properly installed. All parts and
accessories added to the
motorcycle should be genuine
Suzuki parts or their equivalent
designed for use on this motor­cycle. Install and use them
according to their instructions.
If you have any questions, con­tact your Suzuki dealer.

ACCESSORY INSTALLATION GUIDELINES

• Install aerodynamic-affecting
accessories, such as a fairing,
windshield, backrests, saddle­bags, and travel trunks, as low
as possible, as close the
motorcycle and as near to the
center of gravity as is feasible.
Check that the mounting
brackets and other attach­ment hardware are rigidly
mounted.

• Inspect for proper ground
clearance and bank angle.
Inspect that the accessory
does not interfere with the
operation of the suspension,
steering or other control oper­ations.

• Accessories fitted to the han­dlebars or the front fork area
can create serious stability
problems. The extra weight will
cause the motorcycle to be
less responsive to your steer­ing control. The weight may
also cause oscillations in the
front end and lead to instability
problems. Accessories added
to the handlebars or front fork
of the machine should be as
light as possible and kept to a
minimum.

• Certain accessories displace
the rider from his or her normal
riding position. This limits the
freedom of movement of the
rider and may limit control abil­ity.

6-2

• Additional electrical accesso­ries may overload the existing
electrical system. Severe over­loads may damage the wiring
harness or create a hazardous
situation due to the loss of
electrical power during the
operation of the motorcycle.

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

LOADING LIMIT

 WARNING

Overloading or improper load­ing can cause loss of motorcy­cle control and an accident.

Follow loading limits and load­ing guidelines in this manual.

• Never exceed the GVWR
(Gross Vehicle Weight Rating)
of this motorcycle. The GVWR
is the combined weight of the
machine, accessories, pay­load, rider and passenger.
When selecting your accesso­ries, keep in mind the weight of
the riders as well as the weight
of the accessories. The addi­tional weight of the accesso­ries may not only create an
unsafe riding condition but
may also affect the steering
ease.

GVWR: 490 kg (1080 lbs) at the
tire pressure (cold)

Front: 200 kPa

(2.00 kgf/cm

(VL800T)

225 kPa
(2.25 kgf/cm

Rear: 250 kPa

(2.50 kgf/cm2, 36 psi)

6-3

2

, 29 psi)

2

, 33 psi)

LOADING GUIDELINES

This motorcycle is primarily
intended to carry small items
when you are not riding with a
passenger. Follow the loading
guidelines below:

• Balance the load between the
left and right side of the motor­cycle and fasten it securely.

• Keep cargo weight low and as
close to the center of the
motorcycle as possible.

• Do not attach large or heavy
items to the handlebars, front
forks or rear fender.

• Do not install a luggage carrier
or a luggage box protruding
over the tail end of the motor­cycle.

• Do not carry any items that
protrude over the tail end of
the motorcycle.

• Check that both tires are prop­erly inflated to the specified
tire pressure for your loading
conditions. Refer to page 7-36.

• Improperly loading your motor­cycle can reduce your ability to
balance and steer the motor­cycle. You should ride at
reduced speeds, less than 130
km/h (80 mph), when you are
carrying cargo or have added
accessories.

• Adjust suspension setting as
necessary.

MODIFICATION

Modification of the vehicle or
removal of original equipment
may render the vehicle unsafe or
illegal. Obey all applicable regula­tions in your area including federal
and state regulations regarding
environmental protection.
Suzuki’s limited warranties may
not cover damage caused by
modifications that would change
the original vehicle specifications
including, without limitation, modi­fications of any emission-related
parts such as the carburetor(s),
fuel injection system components,
the engine control module, air
suction system components, the
catalytic converter (if equipped),
evaporative emission control sys­tem components (such as the car­bon canister, fuel tank, fuel hoses
and vapor hoses), etc.

It is strictly prohibited to mod­ify a vehicle by installing parts
that can affect emissions con­trol, except in accordance with
very specific U.S. Environmen­tal Protection Agency and Cali­fornia Air Resources Board
regulations.

6-4

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE .............................................................................. 7-2

TOOLS ................................................................................................................. 7-6

GENERAL LUBRICATION ..................................................................................7-6

BATTERY ............................................................................................................ 7-7

AIR CLEANER ................................................................................................... 7-10

SPARK PLUG .................................................................................................... 7-13

ENGINE OIL ....................................................................................................... 7-17

ENGINE IDLE SPEED INSPECTION ................................................................ 7-22

THROTTLE CABLE ADJUSTMENT ................................................................. 7-22

FUEL HOSE ....................................................................................................... 7-23

CLUTCH ADJUSTMENT ................................................................................... 7-25

ENGINE COOLANT ........................................................................................... 7-26

FINAL GEAR OIL ..............................................................................................7-28

BRAKES ............................................................................................................ 7-29

TIRES ................................................................................................................. 7-35

SIDE STAND/IGNITION INTERLOCK SYSTEM ...............................................7-38

FRONT WHEEL REMOVAL .............................................................................. 7-39

REAR WHEEL REMOVAL ................................................................................ 7-41

LIGHT BULB REPLACEMENT ......................................................................... 7-43

FUSES ............................................................................................................... 7-46

CATALYTIC CONVERTER ............................................................................... 7-48

7

7-1

INSPECTION AND
MAINTENANCE

MAINTENANCE, REPLACE­MENT OR REPAIR OF THE
EMISSION CONTROL
DEVICES AND SYSTEMS
MAY BE PERFORMED BY
ANY MOTORCYCLE REPAIR
ESTABLISHMENT OR INDI­VIDUAL USING ANY MOTOR­CYCLE PART WHICH HAS
BEEN CERTIFIED UNDER
THE PROVISIONS IN THE
CLEAN AIR ACT Sec. 207
(a)(2).

MAINTENANCE SCHEDULE

It is very important to inspect and
maintain your motorcycle regu­larly. Follow the guidelines in the
chart. The intervals between peri­odic services in kilometers, miles
and months are shown. At the
end of each interval, be sure to
perform the maintenance listed.

 WARNING

Improper maintenance or fail­ure to perform recommended
maintenance can lead to an
accident.

Keep your motorcycle in good
condition. Ask your Suzuki
dealer or a qualified mechanic
to perform the maintenance
items marked with an asterisk
(*). You may perform the
unmarked maintenance items
by referring to the instructions
in this section, if you have
mechanical experience. If you
are not sure how to do any of
the jobs, ask your Suzuki
dealer to do the maintenance.

7-2

 WARNING

Exhaust gas contains carbon
monoxide, a dangerous gas
that is difficult to detect
because it is colorless and
odorless. Breathing carbon
monoxide can cause death or
severe injury.

Never start the engine or let it
run indoors or where there is
little or no ventilation.

NOTICE

Servicing electric parts with
the ignition switch in the “ON”
position can damage the elec­tric parts when the electric cir­cuit is shorted.

Turn off the ignition switch
before servicing the electric
parts to avoid short-circuit
damage.

NOTICE

Poorly-made replacement parts
can cause your motorcycle to
wear more quickly and may
shorten its useful life.

When replacing parts on your
vehicle, use only genuine
Suzuki replacement parts or
their equivalent.

NOTE: The MAINTENANCE
CHART specifies the minimum
requirements for maintenance. If
you use your motorcycle under
severe conditions, perform main­tenance more often than shown in
the chart. If you have any ques­tions regarding maintenance
intervals, consult your Suzuki
dealer or a qualified mechanic.

7-3

MAINTENANCE CHART

Interval: This interval should be judged by number of months or odom­eter reading, whichever comes first.

Intervalmonths2 12243648

km 1000 6000 12000 18000 24000

Element

Air cleaner element ( 7-10) – I I R I

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

* Valve clearance I – I – I

Spark plugs ( 7-13) – I R I R
Fuel hose ( 7-23) – I I I I
Engine oil ( 7-17) RRRRR
Engine oil filter ( 7-18) R – – R –
Throttle cable play ( 7-22) I I I I I

* Throttle valve synchronization

* Evaporative emission control system

(California model only)

* PAIR (air supply) system – – I – I

“SUZUKI SUPER
LONG LIFE
COOLANT” (Blue)

* Engine coolant

( 7-26)

Radiator hose ( 7-27) –IIII
Clutch ( 7-25) –IIII
Final gear oil ( 7-28) R – I – I

“SUZUKI LONG
LIFE COOLANT”
(Green) or an
engine coolant other
than “SUZUKI
SUPER LONG LIFE
COOLANT” (Blue)

miles 600 4000 7500 11000 14500

I

(CA only)

–– I–I

Replace every 4 years or 48000 km (29000 miles)

––R–R

–I–I

Replace vapor hose ever y 4 years

7-4

Intervalmonths2 12243648

km 1000 6000 12000 18000 24000

Element
*Brakes ( 7-29) IIIII

Brake hose ( 7-29)

Brake fluid ( 7-29)

Tires ( 7-35) – I I I I

*Steering I–I–I

*Front forks ––I–I
* Rear suspension ( 3-21) – – I – I

*Chassis bolts and nuts TTTTT

Lubrication ( 7-6) Lubricate every 1000 km (600 miles)

miles 600 4000 7500 11000 14500

–IIII

* Replace every 4 years

–IIII

* Replace every 2 years

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

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

7-5

TOOLS

A tool kit is provided with your
motorcycle. The toolbox is located
on the left side of the motorcycle.
To open the toolbox, refer to the
SUSPENSION ADJUSTMENT
section.

GENERAL LUBRICATION

Proper lubrication is important for
safe, smooth operation and a long
life for your motorcycle. Be sure
that all lubrication is performed
during periodic maintenance on
the motorcycle. Increase fre­quency when you use your motor­cycle in severe conditions.

NOTICE

Lubricating electrical switches
can damage the switches.

... Motor oil
... Grease

1 Clutch lever pivot
2 Gearshift link pivots
3 Side stand pivot and spring

hook

4 Brake lever pivot
5 Brake pedal pivot

Do not apply grease or oil to
electrical switches.

7-6

BATTERY

The battery is a sealed type bat­tery and requires no mainte­nance. Have your dealer check
the battery’s state of charge peri­odically.

NOTE:

• For charging a sealed type
battery, use a battery charger
applicable to a sealed type
battery.

• If you cannot charge the bat­tery, consult your authorized
Suzuki dealer.

 WARNING

Battery posts, terminals, and
related accessories contain lead
and lead compounds. Lead is
harmful to your health if it gets
into your blood stream.

 WARNING

Batteries produce flammable
hydrogen gas which can
explode if exposed to flames or
sparks.

Keep flames and sparks away
from the battery. Never smoke
when working near the battery.

 WARNING

Wiping the battery with a dry
cloth can cause a static elec­tricity spark, which can start a
fire.

Wipe the battery with a damp
cloth to avoid static electricity
build up.

Wash hands after handling any
parts containing lead.

 WARNING

Diluted sulfuric acid from the
battery can cause blindness or
severe burns.

When working near the battery,
use proper eye protection and
gloves. Flush eyes or body
with ample water and get medi­cal care immediately if you suf­fer injury. Keep batteries out of
reach of children.

NOTICE

Exceeding the maximum
charging rate for the battery
can shorten its life.

Never exceed the maximum
charging rate for the battery.

7-7

Battery Removal

To remove the battery, follow the
procedure below:

1. Place the motorcycle on the
side stand.

2. Remove the bolt 1.

3. Push down the front end of the
rear seat 2 and pull the seat
backward.

4. Remove the bolts 3 and front
seat 4.

5. Disconnect the negative (–)
terminal 5.

6. Remove the cap. Disconnect
the positive (+) terminal 6.

7. Remove the battery 7.

To install the battery:

1. Install the battery in the
reverse order of removal.

2. Connect the battery terminals
securely.

7-8

NOTICE

Reversing the battery lead
wires can damage the charging
system and the battery.

Always attach the red lead to
the (+) positive terminal and the
black (or black with white
tracer) lead to the (–) negative
terminal.

 WARNING

Batteries contain toxic sub­stances including sulfuric acid
and lead. They could cause
injury to humans or could dam­age the environment.

A used battery must be dis­posed of or recycled according
to local law and must not be
discarded with ordinary house­hold waste. Make sure not to
tip over the battery when you
remove it from the vehicle. Oth­erwise, sulfuric acid could run
out and you might be injured.

NOTE:

• Select the same type MF bat­tery when replacing the bat­tery.

• Recharge the battery once a
month if the motorcycle is not
used for a long time.

Pb

The crossed-out wheeled bin
symbol A located on the battery
label indicates that a used battery
should be collected separately
from ordinary household waste.
The chemical symbol of “Pb” B
indicates the battery contains
more than 0.004% lead.

By ensuring the used battery is
disposed of or recycled correctly,
you will help prevent potential
negative consequences for the
environment and human health,
which could otherwise be caused
by inappropriate waste handling
of the battery. The recycling of
materials will help to conserve
natural resources. For more
detailed information about dispos­ing or recycling of the used bat­tery, consult your Suzuki dealer.

7-9

AIR CLEANER

The air cleaner element must be
kept clean to provide good engine
power and gas mileage. If you use
your motorcycle under normal low
stress conditions, you should ser­vice the air cleaner at the intervals
specified. If you ride in dusty, wet,
or muddy conditions, you will
need to inspect the air cleaner
element much more frequently.
Use the following procedure to
remove the element and inspect
it.

 WARNING

Operating the engine without
the air cleaner element in place
can be hazardous. A flame can
spit back from the engine to
the air intake box without the
air cleaner element to stop it.
Severe engine damage can
also occur if dirt enters the
engine due to running the
engine without the air cleaner
element.

NOTICE

Failure to inspect the air
cleaner element frequently if
the vehicle is used in dusty,
wet, or muddy conditions can
damage your motorcycle. The
air cleaner element can
become clogged under these
conditions, and engine damage
may result.

Always check the air cleaner
element after riding in severe
conditions. Clean or replace
the element as necessary. If
water gets in the air cleaner
case, immediately clean the
element and the inside of the
case.

Never run the engine without
the air cleaner element in
place.

7-10

Air Cleaner Element Removal

1. Place the motorcycle on the
side stand.

2. Loosen the clamp bolt 1.

4. Disconnect the tube 5 and
coupler 6.

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

3. Remove the bolts 2 and
unhook the hook 3. Pull the
air cleaner 4.

6. Remove the screws. Remove

the air cleaner element 8.

7-11

7. Carefully use an air hose to
blow the dust from the air
cleaner element.

NOTE: Always apply air pressure
to the mesh side of the air cleaner
element only. If you apply air pres­sure to the fabric side, dirt will be
forced into the pores of the ele­ment, restricting the air flow
through the element.

NOTICE

A torn air cleaner element will
allow dirt to enter the engine
and can damage the engine.

8. Reinstall the air cleaner ele­ment in reverse order of
removal. Be sure that the air
cleaner element is securely in
position and is properly
sealed.

NOTICE

Failure to position the air
cleaner element properly can
allow dirt to bypass the air
cleaner element. This will
cause engine damage.

Be sure to properly install the
air cleaner element.

NOTE: Be careful not to spray
water on the air cleaner box when
cleaning the motorcycle.

Replace the air cleaner element
with a new one if it is torn.
Carefully examine the air
cleaner element for tears
during cleaning.

7-12

Air Cleaner Drain Plug

Remove the plug and drain water
and oil at the periodic mainte­nance interval. The air cleaner
drain plug is located beneath the
air cleaner box.

SPARK PLUG

Your motorcycle comes equipped
with a DENSO X22EPR-U9,
X22ESR-U (California) or NGK
DPR7EA-9, DR7EA (California)
spark plugs. To determine if the
standard spark plug is right for
your usage, check the color of the
plug’s porcelain center electrode
insulator after motorcycle opera­tion. A light brown color indicates
that the plug is correct. A white or
dark insulator indicates that the
engine may need adjustment, or
another plug type may be needed.
Consult your authorized Suzuki
dealer or a qualified mechanic if
your plug insulator is not a light
brown color.

NOTICE

An improper spark plug may
have an incorrect fit or inappro­priate heat range for your
engine. This may cause severe
engine damage which may not
be covered under warranty.

Use one of the spark plugs
listed or their equivalent. Con­sult your Suzuki dealer if you
are not sure which spark plug
is correct for your type of
usage.

7-13

NGK DENSO REMARKS

DPR7EA-9 X22EPR-U9 Standard

If the

DPR8EA-9
DPR9EA-9

X24EPR-U9
X27EPR-U9

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

(California)

NGK DENSO REMARKS

DR7EA X22ESR-U Standard

If the

DR8EA
DR9EA

X24ESR-U
X27ESR-U

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

NOTE: If the above-named plugs
are not available, consult your
authorized Suzuki dealer.

NOTE: This motorcycle uses a
resistor-type spark plug to avoid
jamming electronic parts.
Improper spark plug selection
may cause electronic interfer­ence with your motorcycle’s igni­tion system, resulting in
motorcycle performance prob­lems. Use only the recommended
spark plugs.

Spark Plug Removal

1. Place the motorcycle on the
side stand.

2. Remove the air cleaner by
referring to the AIR CLEANER
section.

3. Remove the bolt and air
cleaner bracket 1.

FRONT

REAR

4. Remove the bolt and open the
cover 2.

7-14

FRONT

REAR

FRONT (California model)

REAR (California model)

5. Pull off the spark plug caps.

6. Remove the spark plugs with a
spark plug wrench.

7-15

SPARK PLUG CLEANING

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

0.8 – 0.9 mm
(0.031 – 0.035 in)

Installation

NOTICE

Improper installation of the
spark plug can damage your
motorcycle. An overly-tight or
cross-threaded spark plug will
damage the aluminum threads
of the cylinder head.

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

Carefully turn the spark plug
by hand into the threads. If the
spark plug is new, tighten it
with a wrench about 1/2 turn
past finger tight. If you are
reusing the old spark plug,
tighten it with a wrench about
1/8 turn past finger tight.

NOTICE

Dirt can damage the moving
engine parts of your motorcy­cle if it enters an open spark
plug hole.

Cover the spark plug hole
while the spark plug is out of
the hole.

7-16

ENGINE OIL

Engine life depends on oil amount
and quality. Daily engine oil level
checks and periodic changes are
two of the most important mainte­nance items to be performed.

NOTICE

Operating the motorcycle with
too little or too much oil can
damage the engine.

Engine Oil Level Check

Follow the procedure below to
inspect the engine oil level.

1. Start the engine and allow it to
idle for three minutes.

2. Stop the engine and wait
approximately three minutes.

3. Hold the motorcycle vertically
and inspect the engine oil level
through the engine oil level
inspection window. The engine
oil level should be between the
“L” (low) and the “F” (full) lines.

Place the motorcycle on level
ground. Check the oil level with
the engine oil inspection win­dow before each use of the
vehicle. Be sure the engine oil
level is always above the “L”
(low) line and not higher than
the “F” (full) line.

7-17

ENGINE OIL AND FILTER
CHANGE

Change the engine oil and oil filter
at the scheduled times. The
engine should always be warm
when the engine oil is changed so
the engine oil will drain easily. The
procedure is as follows:

1. Place the motorcycle on level
ground on the side stand.

 CAUTION

Hot engine oil and exhaust
pipes can burn you.

Wait until the engine oil drain
plug and exhaust pipes cool
before draining oil.

 WARNING

Children and pets may be
harmed by swallowing new or
used oil. Repeated, prolonged
contact with used engine oil
may cause skin cancer. Brief
contact with oil may irritate
skin.

2. Remove the oil filler cap 1.

3. Remove the drain plug 2 and
gasket 3 from the bottom of
the engine and drain the
engine oil into a drain pan.

Keep new and used oil and
used oil filters away from chil­dren and pets. To minimize
your exposure to used oil, wear
a long-sleeve shirt and mois­ture-proof gloves (such as
dishwashing gloves) when
changing oil. If oil contacts
your skin, wash thoroughly
with soap and water. Launder
any clothing or rags if wet with
oil. Recycle or properly dis­pose of used oil and filters.

7-18

NOTICE

Turning the engine while drain­ing the engine oil will cause oil
film shortage and adversely
affect the engine.

Do not use the electric starter
switch during engine oil
replacement work.

NOTE:

• Recycle or properly dispose of
used oil.

• Before starting the work, check
that there is not any dust, mud,
or foreign object inside the oil
jug or on the oil filter mounting
surface.

4. Turn the oil filter 4 with a

Suzuki “cap type” oil filter
wrench or a “strap type” filter
wrench of the proper size and
remove the oil filter.

5. Wipe off the mounting surface

5 on the engine where the
new filter will be seated with a
clean rag.

Oil filter wrench
(Part No. 09915-40620)

7-19

6. Smear a little engine oil

Mark top dead center

Oil filter wrench

Tighten the filter 2 turns or to
specified torque.

In the position at which the
filter gasket first contacts
the mounting surface.

around the rubber gasket 6 of
the new oil filter.

NOTICE

Failure to use an oil filter with
the correct design and thread
specifications can damage
your motorcycle’s engine.

Be sure to use a genuine
Suzuki oil filter or an equiva­lent one designed for your
motorcycle.

7. Screw the new filter by hand
until the filter gasket contacts
the mounting surface (a small
resistance will be felt).

NOTE: To tighten the oil filter
properly, it is important to accu­rately identify the position at
which the filter gasket first con­tacts the mounting surface.

8. Mark the top dead center posi­tion on the “cap type” filter
wrench or on the oil filter. Use
an oil filter wrench to tighten
the filter 2 turns or to specified
torque.

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

7-20

9. Replace the drain plug gasket
with a new one. Reinstall the
drain plug and gasket. Tighten
the plug securely with a torque
wrench. Reinstall the drain
plug and tighten it securely.
Pour about 3400 ml (3.6 US
qt) of the specified oil in the
filler hole. (See FUEL, OIL
AND COOLANT RECOM­MENDATIONS section.)

Drain plug tightening torque:
21 N·m (2.1 kgf-m, 15.0 lbf-ft)

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

NOTICE

Engine damage may occur if
you use oil that does not meet
Suzuki’s specifications.

Be sure to use the oil specified
in the FUEL, OIL AND COOL­ANT RECOMMENDATIONS sec­tion.

10.Start the engine (while the
motorcycle is outside on level
ground) and allow it to idle for
three minutes.

11.Turn the engine off and wait
approximately three minutes.
Hold the motorcycle vertically
and recheck the oil level on the
engine oil inspection window.
The oil level should be at the
“F” (full) line. If it is lower than
the “L” line, add oil until the oil
level is between the “L” line
and the “F” line. Inspect the
areas around the drain plug
and oil filter for leaks.

NOTE: If you do not have a proper
oil filter wrench, have your autho­rized Suzuki dealer or a qualified
mechanic perform this service.

7-21

ENGINE IDLE SPEED INSPECTION

Inspect the engine idle speed.
The engine idle speed should be
1000 – 1200 r/min when the
engine is warm.

NOTE: If the engine idle speed is
not within the specified range, ask
your Suzuki dealer or a qualified
mechanic to inspect and repair
the motorcycle.

THROTTLE CABLE ADJUSTMENT

2.0 – 4.0 mm
(0.08 – 0.16 in)

To adjust the cable play:

1. Loosen the lock nut 1.

2. Turn the adjuster 2 so that the
throttle grip has 2.0 – 4.0 mm
(0.08 – 0.16 in) play.

3. Tighten the lock nut 1.

 WARNING

Inadequate throttle cable play
can cause engine speed to rise
suddenly when you turn the
handlebars. This can lead to
loss of control and an accident.

Adjust the throttle cable play
so that engine idle speed does
not rise due to handlebar
movement.

7-22

Throttle Cable Boots

The throttle cable has a boots.
Check that the boots are fit
securely. Do not apply water
directly to the boots when wash­ing. Wipe off dirt from the boots
with a wet cloth when the boots
are dirty.

FUEL HOSE

Fuel Tank Lift

1. Place the motorcycle on the
side stand. Remove the seat
by referring to the BATTERY
section.

2. Remove the bolt 1.

3. Unhook the hooks. Disconnect
the coupler 2 and remove the
instrument panel assembly.

7-23

4. Remove the bolt 3. Raise the

rear end of the fuel tank and
slide it backward.

NOTE: Lifting up the fuel tank too
much can result in the fuel hose
becoming bent or twisted. Lift the
fuel tank as little as possible and
disconnect the fuel hose. The fuel
tank in the above illustration is
lifted to show the fuel hose and
coupler clearly.

Reinstall the fuel tank.

NOTE: Check that the fuel tank
drain hose and breather hose are
not bent before reinstalling the
fuel tank.

(For California)

5. Inspect the fuel hose for dam­age and fuel leakage. If any
defects are found, the fuel
hose must be replaced.

7-24

CLUTCH ADJUSTMENT

Clutch cable play should be 10 –
15 mm (0.4 – 0.6 in) measured at
the clutch lever end. Adjust clutch
cable play according to the follow­ing procedure:

Minor Adjustment

10 – 15 mm
(0.4 – 0.6 in)

Loosen the lock nut 2. Turn the
clutch cable adjuster 1 to provide
the specified play.

Major Adjustment

1. Loosen the lock nuts 3. Turn
the lock nuts 3 counterclock­wise.

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

7-25

3. Loosen the lock nut 6.

F

L

4. Turn in the adjuster 7 until it

stops. Turn back the adjuster
7 1/4 turns.

5. Hold the adjuster 7 with a

screwdriver and tighten the
lock nut 6.

6. Turn the lock nuts 3 to obtain

approximately 10 – 15 mm
(0.4 – 0.6 in) of free play at the
clutch lever end as indicated.

7. If proper free play is not avail­able, loosen and turn the lock
nuts 3 until clutch lever has
proper free play.

8. Tighten the lock nuts 2 and

3.

ENGINE COOLANT

Coolant level

The engine coolant solution
should be between “F” (full) and
“L” (low) level lines on the engine
coolant reservoir. If the level is
lower than “L” (low) level line,
bring it up to “F” (full) level by add­ing specified engine coolant.

NOTE:

• Check the coolant level when
the engine is cold.

• If the engine coolant reservoir
is empty, check the radiator
coolant level.

NOTE: Minor adjustment can be
performed at the clutch lever side
adjuster only.

7-26

To add specified engine coolant:

1. Place the motorcycle on the
side stand.

2. Remove the bolts 1 and cover

2.

3. Remove the filler cap and add
specified engine coolant
through the filler hole.

 WARNING

Engine coolant is harmful or
fatal if swallowed or inhaled.
Solution can be poisonous to
animals.

Do not drink antifreeze or cool­ant solution. If swallowed, do
not induce vomiting. Immedi­ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Keep out of the
reach of children and animals.

NOTE: Adding only water will
dilute the engine coolant and
reduce its effectiveness. Add
specified engine coolant.

Radiator Hose Inspection

Inspect the radiator hoses for
cracks, damage or engine coolant
leakage. If any defects are found,
ask your Suzuki dealer to replace
the radiator hose with a new one.

7-27

FINAL GEAR OIL

Change the gear oil as follows:

1. Place the motorcycle on the
side stand.

 WARNING

Operating the motorcycle with
too little final gear oil can
cause the final drive unit to
lock up and cause an accident.

Check for leaks and the correct
level of final gear oil before
each use. Add oil if necessary.
Tighten the drain plug securely
after changing the gear oil.

2. Remove the oil filler cap 1.

3. Drain the oil into a suitable
container by removing the
drain plug 2 from the bottom
of the final gear case.

4. Reinstall the drain plug and
tighten it securely after all the
oil has been drained out. Hold
the motorcycle vertically and
pour fresh oil through the filler
hole until the oil level reaches
the oil filler hole. Approxi­mately 200 – 220 ml (6.8 – 7.4
US oz) of oil will be required.

5. Reinstall the oil filler cap.

 WARNING

Children and pets may be
harmed by swallowing new or
used oil. Repeated, prolonged
contact with used engine oil
may cause skin cancer. Brief
contact with oil may irritate
skin.

Keep new and used oil and
used oil filters away from chil­dren and pets. To minimize
your exposure to used oil, wear
a long-sleeve shirt and mois­ture-proof gloves (such as
dishwashing gloves) when
changing oil. If oil contacts
your skin, wash thoroughly
with soap and water. Launder
any clothing or rags if wet with
oil. Recycle or properly dis­pose of used oil and filters.

NOTE: Recycle or properly dis­pose of used oil.

7-28

BRAKES

This motorcycle has front disk
and rear drum brakes.

 WARNING

Failure to properly inspect and
maintain your motorcycle’s
brake systems can increase
your chance of having an acci­dent.

FRONT BRAKE
Brake Fluid

Be sure to inspect the brakes
before each use according to
the INSPECTION BEFORE RID­ING section. Always maintain
your brakes according to the
MAINTENANCE SCHEDULE.

NOTE: Operating in mud, water,
sand or other extreme conditions
can cause accelerated brake
wear. If you operate your motorcy­cle under these conditions, the
brakes must be inspected more
often than recommended in the
MAINTENANCE SCHEDULE.

Brake Hose Inspection

Inspect the brake hoses and hose
joints for cracks, damage or brake
fluid leakage. If any defects are
found, ask your Suzuki dealer to
replace the brake hose with a new
one.

Check the brake fluid level in the
front brake fluid reservoir and
inspect for brake pad wear and
leaks.

 WARNING

Brake fluid will gradually
absorb moisture through the
brake hoses. Brake fluid with
high water content lowers the
boiling point and can cause
brake system malfunction due
to corrosion of brake compo­nents. Boiling brake fluid or
brake system malfunction
could result in an accident.

Replace the brake fluid every
two years to maintain braking
performance.

7-29

 WARNING

The use of any fluid except
DOT4 brake fluid from a sealed
container can damage the
brake system and lead to an
accident.

Clean filler cap before remov­ing. Use only DOT4 brake fluid
from a sealed container. Never
use or mix with different types
of brake fluid.

 WARNING

Brake fluid is harmful or fatal if
swallowed, and harmful if it
comes in contact with skin or
eyes. Solution can be poison­ous to animals.

If brake fluid is swallowed, do
not induce vomiting. Immedi­ately contact a poison control
center or a physician. If brake
fluid gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Keep out of the
reach of children and animals.

NOTICE

Spilled brake fluid can damage
painted surfaces and plastic
parts.

Be careful not to spill any fluid
when filling the brake fluid res­ervoir. Wipe spilled fluid up
immediately.

NOTE: SUZUKI highly recom­mends the use of ECSTAR brand
brake fluid. ECSTAR has been
specially formulated for your
SUZUKI product and contributes
to the desired motorcycle perfor­mance and ideal riding experi­ence.

7-30

Brake Pads

Inspect the front brake pads to
see if they are worn down to the
grooved wear limit lines 1. If a
pad is worn to the grooved wear
limit line, it must be replaced with
a new one. After replacing the
front brake pads, the brake lever
must be pumped several times.
This will extend the pads to their
proper position.

 WARNING

Failure to inspect and maintain
the brake pads and replace
them when recommended can
increase your chance of having
an accident.

If you need to replace brake
pads, have your Suzuki dealer
do this work. Inspect and main­tain the brake pads as recom­mended.

 WARNING

If you ride this motorcycle after
brake system repair or brake
pad replacement without
pumping the brake lever, you
may get poor braking perfor­mance which could result in an
accident.

After brake system repair or
brake pad replacement, pump
the brake lever several times
until brake pads are pressed
against the brake disks and
proper lever stroke and firm
feel are restored.

7-31

NOTE: Do not squeeze the brake
lever when the pads are not in
their positions. It is difficult to push
the pistons back into position.

 WARNING

Replacing only one of the two
brake pads can result in
uneven braking action and can
increase your chance of having
an accident.

Rear Brake Pedal Adjustment

 WARNING

Too much play in the rear brake
pedal can cause poor braking
performance and may lead to
an accident. Too little play may
force brake shoes to rub
against the drum at all times,
causing damage to the shoes
and the drum.

Always replace both pads
together.

Follow the steps in this section
to adjust the rear brake pedal
properly.

7-32

The rear brake pedal position and
the free travel must be properly
adjusted. Adjust the brake pedal
in the following manner:

95 – 105 mm
(3.7 – 4.1 in)

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

2. Adjust the brake pedal height
by turning the pedal stopper
bolt 2 to locate the pedal 95 –
105 mm (3.7 – 4.1 in) above
the top face of the footrest.

3. Tighten the lock nut.

20 – 30 mm
(0.8 – 1.2 in)

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

7-33

Brake Lining Wear Limit

The motorcycle is equipped with
the brake lining wear limit indica­tor on rear brake. To check wear
of the brake lining perform the fol­lowing:

3. If the extension line is out side
this range as shown in the Fig.
B, have the brake shoes
replaced by your authorized
Suzuki dealer or a qualified
mechanic.

Range Index mark

Fig.A The extension line of the

index mark is within the
range.

Fig.B The extension line of the

index mark is out of the
range.

1. Make sure the brake play is
properly adjusted.

2. While fully applying the brake
check to see that the extension
line of the index mark is within
the range on the brake panel
as shown in Fig A.

 WARNING

Riding with worn brake shoes
will reduce braking perfor­mance and will increase your
chance of having an accident.

Inspect brake shoe wear before
each use. Ask your Suzuki
dealer or a qualified mechanic
to replace brake shoes if the
shoes are worn to the limit.

REAR BRAKE LIGHT SWITCH

To adjust the brake light switch,
hold the switch body and turn the
adjuster so that the brake light will
come on just before a pressure
rise is felt when the brake pedal is
depressed.

7-34

TIRES

 WARNING

The tires on your motorcycle
form the crucial link between
your motorcycle and the road.
Failure to take the precautions
below may result in an accident
due to tire failure.

• Check tire condition and
pressure before each ride,
and adjust pressure if neces­sary.

• Avoid overloading your
motorcycle.

• Replace a tire when worn to
the specified limit, or if you
find damage such as cuts or
cracks.

• Always use the size and type
of tires specified in this
owner’s manual.

• Balance the wheel after tire
installation.

• Read this section of the
owner’s manual carefully.

 WARNING

Failure to perform break-in of
the tires could cause tire slip
and loss of control, which
could result in an accident.

Use extra care when riding on
new tires. Perform proper
break-in of the tires referring to
the BREAK-IN section of this
manual and avoid hard acceler­ation, hard cornering, and hard
braking for the first 100 miles
(160 km).

7-35

Tire Pressure and Loading

Proper tire pressure and proper
tire loading are important factors.
Overloading your tires can lead to
tire failure and loss of motorcycle
control.

Check tire pressure each day
before you ride, and adjust tire
pressure according to the table
below. Tire pressure should only
be checked and adjusted before
riding since riding will heat up the
tires and lead to higher inflation
pressure readings.

VL800

LOAD

FRONT

REAR

SOLO RIDING

WITH LIGHT

OR LITTLE

CARGO LOAD

200 kPa

2.00 kgf/cm2
29 psi

250 kPa

2.50 kgf/cm2
36 psi

DUAL RIDING

OR SOLO

RIDING

WITH HEAVY

CARGO LOADTIRE

200 kPa

2.00 kgf/cm2
29 psi

250 kPa

2.50 kgf/cm2
36 psi

Under-inflated tires make smooth
cornering difficult, and can result
in rapid tire wear. Over-inflated
tires cause a smaller amount of
tire to be in contact with the road,
which can contribute to skidding
and loss of control.

Tire Condition and Type

Tire condition and tire type affect
motorcycle performance. Cuts or
cracks in the tires can lead to tire
failure and loss of motorcycle con­trol. Worn tires are susceptible to
puncture failures and subsequent
loss of motorcycle control. Tire
wear also affects the tire profile,
changing motorcycle handling
characteristics.

VL800T

LOAD

FRONT

REAR

SOLO RIDING

WITH LIGHT

OR LITTLE

CARGO LOAD

225 kPa

2.25 kgf/cm
33 psi

250 kPa

2.50 kgf/cm2
36 psi

DUAL RIDING

WITH HEAVY

CARGO LOADTIRE

2

OR SOLO

RIDING

225 kPa

2.25 kgf/cm
33 psi

250 kPa

2.50 kgf/cm
36 psi

Check the condition of your tires
each day before you ride. Replace
tires if tires show visual evidence
of damage, such as cracks or
cuts, or if tread depth is less than

1.6 mm (0.06 in) front, 2.0 mm

2

(0.08 in) rear.

2

7-36

NOTE: The “Triangle mark” indi­cates the place where the wear
bars are molded into the tire.
When the wear bars contact the
road, it indicates that the tire wear
limit has been reached.

Whenever you replace a tire, use
a tire of the size and type listed
below. If you use a different size
or type of tire, motorcycle han­dling may be adversely affected,
possibly resulting in loss of motor­cycle control.

VL800

FRONT REAR

SIZE

TYPE IRC GS-23F IRC GS-23R

130/90-16M/C

67H

170/80-15M/C

77H

VL800T

FRONT REAR

SIZE

TYPE

130/90-16M/C

67H

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

170/80-15M/C

77H

Always balance the wheel after
repairing a puncture or replacing
the tire. Proper wheel balance is
important to avoid variable wheel­to-road contact, and to avoid
uneven tire wear.

 WARNING

An improperly repaired,
installed, or balanced tire can
cause loss of control and an
accident, or can wear out
sooner.

• Ask your Suzuki dealer or a
qualified mechanic to per­form tire repair, replacement,
and balancing because
proper tools and experience
are required.

• Install tires according to the
rotation direction shown by
arrows on the sidewall of
each tire.

7-37

SIDE STAND/IGNITION INTERLOCK SYSTEM

 WARNING

If the side stand/ignition inter­lock system is not working
properly, it is possible to ride
the motorcycle with the side
stand in the down position.
This may interfere with rider
control during a left turn and
could cause an accident.

Check the side stand/ignition
interlock system for proper opera­tion as follows:

1. Sit on the motorcycle in the
normal riding position, with the
side stand up.

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

3. While continuing to hold the
clutch in, move the side stand
to the down position.

If the engine stops running when
the side stand is moved to the
down position, then the side
stand/ignition interlock system is
working properly. If the engine
continues to run with the side
stand down and the transmission
in gear, then the side stand/igni­tion interlock system is not work­ing properly. Have your
motorcycle inspected by an
authorized Suzuki dealer or some
other qualified service mechanic.

Check the side stand/ignition
interlock system for proper
operation before riding. Check
that the side stand is returned
to its full up position before
starting off.

7-38

FRONT WHEEL REMOVAL

1. Place the motorcycle on the
side stand.

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

NOTICE

Improper jacking may cause
damage to the oil filter.

Do not place the jack under the
oil filter when jacking up the
motorcycle.

4. Turn the axle counterclockwise
and draw it out.

NOTE: A special tool is necessary
to loosen the axle. The special
tool is available at your Suzuki
dealer.

3. Place an accessory service
stand or equivalent under the
swingarm to help stabilize the
rear end. Carefully position a
jack under the engine or chas­sis tubes and raise the jack
until the front wheel is slightly
off the ground.

5. Remove the speed sensor 3.

7-39