Suzuki Intruder VL800 (2001-2009) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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SUZUKI INTRUDER VL800 (2001-2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS

- English Service Manual / Repair Manual, Owners Manual and Wiring Diagrams, for motorcycles Suzuki Intruder VL800 (2001-2009).
 

CONTENTS:

SERVICE MANUAL

Foreword
- How To Use This Manual
- To Locate What You Are Looking For:
- Component Parts And Work To Be Done
- Symbol
01 General Information
- Warning/Caution/Note
- General Precautions
- Suzuki Vl800k1 (2001-Model)
- Serial Number Location
- Fuel, Oil And Engine Coolant Recommendation
- Fuel
- Engine Oil
- Gear Oil (Final Drive Gear Oil)
- Brake Fluid
- Front Fork Oil
- Engine Coolant
- Break-In Procedures
- Cylinder Identification
- Information Labels
- Specifications
- Country And Area Codes
02 Periodic Maintenance
- Periodic Maintenance Schedule
- Periodic Maintenance Chart
- Lubrication Points
- Maintenance And Tune-Up Procedures
- Air Cleaner
- Spark Plug
- Valve Clearance
- Engine Oil And Oil Filter
- Fuel Hose
- Engine Idle Speed
- Pair (Air Supply) System
- Throttle Cable Play
- Clutch
- Cooling System
- Final Gear Oil
- Brake
- Tires
- Steering
- Front Fork
- Rear Suspension
- Exhaust Pipe Bolt And Nut
- Chassis Bolts And Nuts
- Compression Pressure Check
- Oil Pressure Check
03 Engine
- Engine Components Removable With Engine In Place
- Engine Removal And Installation
- Engine Removal
- Engine Installation
- Engine Disassembly
- Engine Components Inspection And Servicing
- Cylinder Head Cover
- Camshaft
- Cam Chain Tensioner And Guide
- Cylinder Head
- Piston
- Conrod/Crankshaft
- Clutch
- Generator/Signal Generator/ Starter Clutch
- Oil Pump
- Transmission
- Gearshift Fork
- Oil Jet
- Crankcase
- Engine Reassembly
04 Shaft Drive
- Secondary Bevel Gears
- Construction
- Removal
- Disassembly
- Inspection
- Secondary Gear Shims Adjustment
- Reassembly
- Installation
- Final Bevel Gears
- Construction
- Final Gear Case Removal
- Final Gear Case Disassembly
- Final Gear Shims Adjustment
- Final Gear Case Reassembly
- Final Gear Case Installation
05 Fuel And Lubrication System
- Fuel System
- Fuel Pump
- Fuel Tank/Fuel Valve
- Removal
- Inspection
- Remounting
- Fuel Pump
- Removal
- Inspection
- Reassembly
- Carburetor
- Construction
- Specifications
- Diaphragm And Piston Operation
- Slow System
- Transient Enrichment System
- Main System
- Starter (Enricher) System
- Float System
- Accelerator Pump System
- Removal
- Disassembly
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Heater And Thermo-Switch Inspection
- Float Height Adjustment
- Reassembly And Reinstallation
- Lubrication System Chart
- Pair (Air Supply) System Inspection
06 Cooling System
- Engine Coolant
- Radiator And Water Hose
- Cooling Circuit Inspection
- Radiator Removal
- Radiator Cap Inspection
- Radiator Inspection And Cleaning
- Radiator Remounting
- Water Hose Inspection
- Cooling Fan
- Inspection
- Removal
- Installation
- Cooling Fan Thermo-Switch
- Removal
- Inspection
- Installation
- Engine Coolant Temperature Switch
- Removal
- Inspection
- Thermostat
- Removal
- Inspection
- Installation
- Water Pump
- Removal And Disassembly
- Inspection
- Reassembly And Installation
07 Chassis
- Exterior Parts
- Removal
- Remounting
- Front Wheel
- Construction
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Front Brake
- Construction
- Brake Pad Replacement
- Brake Fluid Replacement
- Caliper Removal And Disassembly
- Caliper Inspection
- Caliper Reassembly And Remounting
- Brake Disc Inspection
- Master Cylinder Removal And Disassembly
- Master Cylinder Inspection
- Master Cylinder Reassembly And Remounting
- Front Fork
- Construction
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Steering
- Construction
- Removal And Disassembly
- Inspection And Disassembly
- Reassembly And Remounting
- Rear Wheel
- Construction
- Removal
- Disassembly
- Inspection And Disassembly
- Reassembly And Remounting
- Rear Brake
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Rear Brake Rod Removal And Disassembly
- Reassembly And Remounting
- Rear Suspension
- Construction
- Removal
- Inspection And Disassembly
- Reassembly
- Remounting
08 Electrical System
- Cautions In Servicing
- Location Of Electrical Components
- Charging System
- Troubleshooting
- Inspection
- Starter System And Side-Stand/Ignition Interlock System
- Troubleshooting
- Starter Motor Removal And Disassembly
- Starter Motor Inspection
- Starter Motor Reassembly
- Starter Relay Inspection
- Side Stand/Ignition Interlock System Parts Inspection
- Ignition System
- Troubleshooting
- Inspection
- Speedometer
- Removal
- Parts Names
- Operating Procedure
- Inspection
- Lamps
- Relays
- Switches
- Battery
- Specifications
- Initial Charging
- Servicing
- Recharging Operation
09 Servicing Information
- Troubleshooting
- Engine
- Carburetor
- Shaft Drive
- Chassis
- Brakes
- Electrical
- Battery
- Wiring Diagram (For E-02, 19 / For E-03, 28, 33 / For E-24)
- Wire Harness, Cable And Hose Routing
- Wire Harness Routing
- Cable Routing
- Fuel Hose Routing
- Cooling Hose Routing
- Front Brake Hose Routing
- Battery Protector
- Speed Sensor Lead Wire Routing
- Special Tools
- Tightening Torque
- Engine
- Secondary And Final
- Chassis
- Tightening Torque Chart
- Service Data
10 Emission Control Information
- Emission Control Carburetor Components
- Evaporative Emission Control System
- Canister Hose Routing
- Evaporative Emission Control System Inspection
11 Vl800k2 ('02-Model)
- Specifications
- Service Data
12 Vl800k3 (’03-Model)
- Specifications
- Service Data
- Wiring Diagram
13 Vl800k4 (’04-Model)
- Specifications
- Service Data
- Periodic Maintenance Chart
- Cooling Hose Routing
- Rear Combination Light Installation
- Wiring Diagram
14 Vl800k5 (’05-Model)
- Specifications
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- Service Data
- Periodic Maintenance Chart
- Precautions In Servicing
- Fi System Technical Features
- Self-Diagnosis Function
- Fail-Safe Function
- F1 System Troubleshooting
- Ecm Terminal
- Sensors
- Fuel Delivery System
- Fuel System
- Throttle Body
- Emission Control Systems
- Pair (Air Supply) System And Emission Control System Inspection
- Evaporative Emission Control System Inspection (Only For E-33)
- Tightening Torque
- Wiring Harness, Cable And Hose Routing
- Pair (Air Supply) System Diagram
- Pair (Air Supply) System Hose Routing
- Evap Canister Hose Routing (Only For E-33)
- Fuel Feed Hose Routing
- Special Tools
15 Vl800tk5 (’05-Model)
- Specifications
- Service Data
16 Vl800/Tk6 ('06-Model)
- Specifications
- Service Data
- Special Tools
- Conrod/Crankshaft
- Emission Control Systems
17 Vl800/Tk7 (’07-Model)
- Specifications
- Service Data
- Fuel Pump And Fuel Level Gauge Removal
- Fuel Pump And Fuel Level Gauge Installation
- Fuel Level Meter Inspection
- Fuel Level Gauge Inspection
- Cable Routing
- Front Brake Hose Routing
18 Vl800/C/Tk9 (’09-Model)
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- Country And Area Codes
- Specifications
- Periodic Maintenance Schedule
- Periodic Maintenance Chart
- Maintenance And Tune-Up Procedures
- Air Cleaner
- Spark Plug
- Valve Clearance
- Engine Oil And Oil Filter
- Throttle Cable Play
- Throttle Valve Synchronization
- Evaporative Emisson Control System (E-33 Only)
- Compression Pressure Check
- Compression Test Procedure
- F1 System Diagnosis
- F1 System Wiring Diagram
- Ecm Terminal
- Fail-Safe Function
- Dtc Table And Defective Condition
- Dtc Troubleshooting
- Throttle Body
- Construction
- Throttle Body Removal
- Throttle Body Disassembly
- Throttle Body Cleaning
- Throttle Body Inspection
- Throttle Body Reassembly
- Throttle Body Installation
- Stp Sensor Adjustment
- Tp Sensor Adjustment
- Isc Valve Removal
- Isc Valve Installation
- Isc Valve Inspection
- Isc Valve Preset And Opening Initialization
- Throttle Valve Synchronization
- Ignition System
- Inspection
- Combination Meter Inspection
- Led (Light Emitting Diode)
- Fuel Level Meter Inspection
- Wiring Harness Routing
- Cable Routing
- Throttle Body Installation
- Ignition Coil Installation
- Engine Mounting
- Muffler & Exhaust Pipe Installation
- Pair (Air Supply) System Hose Routing
- Rear Combination Light Installation
- Special Tools
- Tightening Torque
- Engine
- F1 System And Intake Air System
- Service Data
- Emission Control System
- Exhaust Emission Control System (Pair System)
- Evaporative Emission Control System (Only For E-33)
- Pair (Air Supply) System Inspection
- Heated Oxygen Sensor (Ho2s) Inspection (For E-02, 19, 24, 33)
- Evaporative Emission Control System Inspection (Only For E-33)
- Evap System Purge Control Solenoid Valve
- Fuel Shut-Off Valve
- Pair (Air Supply) System Diagram
- Pair (Air Supply) System Hose Routing
- Evap Canister Hose Routing (Only For E-33)
- Wiring Diagram
19 Wiring Diagram

OWNERS MANUAL