Suzuki VZR1800 - Repair, Service Manual, Wiring Diagrams and Owners Manual

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SUZUKI VZR1800 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS

- English Service Manual / Repair Manual, Owners Manual and Wiring Diagrams, for motorcycles Suzuki VZR1800.

 
CONTENTS:

2006 SERVICE MANUAL

99500-39290-01e vzr1800 service manual
- foreword_group index
- how to use this manual
- to locate what you are looking for:
- component parts and work to be done
- symbol
- abbreviations used in this manual
- wire color
- 01 general information
- warning/caution/note
- general precautions
- suzuki vzr1800k6 (’06-model)
- serial number location
- fuel, oil and engine coolant recommendation
- break-in procedures
- cylinder identification
- information labels
- specifications
- 02 periodic maintenance
- periodic maintenance schedule
- maintenance and tune-up procedures
- compression pressure check
- oil pressure check
- sds check
- 03 engine
- engine components removable with engine in place
- engine removal and installation
- engine disassembly
- engine components inspection and service
- engine reassembly
- 04 driveline/axle
- secondary bevel gears
- final bevel gears
- 05 fi system diagnosis
- precautions in servicing
- fi system technical features
- ecm terminal
- self-diagnosis function
- fail-safe function
- fi system troubleshooting
- sensors
- 06 fuel system and throttle body
- fuel delivery system
- fuel system
- throttle body
- 07 exhaust system
- excva (exhaust control valve actuator) and excv (exhaust control valve)
- exhaust pipe and muffler
- 08 cooling and lubrication system
- engine coolant
- cooling circuit
- radiator and water hose
- cooling fan
- ect sensor
- thermostat
- water pump
- engine lubrication system chart
- 09 chassis
- exterior parts
- front wheel
- front fork
- steering
- handlebars
- rear wheel
- rear suspension
- front brake
- rear brake
- tire and wheel
- 10 electrical system
- cautions in servicing
- location of electrical components
- charging system
- starter system and side-stand/ignition interlock system
- ignition system
- speedometer and tachometer
- lamps
- relays
- battery
- 11 servicing information
- troubleshooting
- tightening torque
- service data
- wiring harness, cable and hose routing
- 12 emission control information
- emission control systems
- pair (air supply) system and emission control system inspection
- pair (air supply) system hose routing (for e-03, 28, 33)
- pair (air supply) system hose routing (for the others)
- heated oxgen sensor (ho2s) inspection (for e-02, 19, 24)
- 13 wiring diagram
- update vzr 1800


2006-09 SERVICE MANUAL

foreword
how to use this manual
- to locate what you are looking for
- component parts and work to be done
- symbol
- abbreviations used in this manual
- sae-to-former suzuki term
- wire color
01 general information
- warning/caution/note
- general precautions
- suzuki vzr1800k6 (’06-model)
- serial number location
- fuel, oil and engine coolant recommendation
- fuel (for usa and canada)
- fuel (for other countries)
- engine oil (for usa)
- engine oil (for other countries)
- gear oil (final drive gear oil)
- brake fluid
- front fork oil
- engine coolant
- break-in procedures
- cylinder identification
- information labels
- specifications
- dimensions and dry mass
- engine
- drive train
- chassis
- electrical
- capacities
02 periodic maintenance
- periodic maintenance schedule
- periodic maintenance chart
- lubrication points
- maintenance and tune-up procedures
- air cleaner
- exhaust pipe bolts and muffler bolts
- exhaust control valve
- valve clearance
- spark plug
- fuel line
- evaporative emission control system (e-33 only)
- engine oil and oil filter
- final gear oil
- throttle cable play
- pair (air supply) system
- throttle valve synchronization
- cooling system
- clutch cable play
- brake
- tires
- steering
- front fork
- rear suspension
- chassis bolts and nuts
- compression pressure check
- compression test procedure
- oil pressure check
- sds check
03 engine
- engine components removable with engine in place
- engine removal and installation
- engine removal
- engine installation
- engine disassembly
- engine components inspection and service
- cylinder head cover
- camshaft
- cam chain tension adjuster
- cam chain tensioner
- cam chain guide
- cylinder head and valve
- cylinder
- piston and piston ring
- clutch
- gearshift cover
- starter clutch
- oil pump
- starter torque limiter
- generator cover
- clutch release camshaft
- water pump
- gearshift
- oil pressure regulator
- oil strainer
- transmission
- crankcase
- balancer driven gear
- crankshaft and conrod
- crankshaft journal bearing
- crankshaft thrust bearing
- engine reassembly
04 driveline/axle
- secondary bevel gears
- construction
- removal
- disassembly
- inspection
- reassembly
- secondary gear shims adjustment
- 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 fi system diagnosis
- precautions in servicing
- electrical parts
- fuse
- ecm/various sensors
- electrical circuit inspection procedure
- using the multi-circuit tester
- fi system technical features
- injection time (injection volume)
- compensation of injection time (volume)
- injection stop control
- fi system parts location
- fi system wiring diagram
- ecm terminal
- self-diagnosis function
- user mode
- dealer mode
- tps adjustment
- fail-safe function
- fi system troubleshooting
- customer complaint analysis
- visual inspection
- self-diagnostic procedures
- self-diagnosis reset procedure
- use of sds diagnostic procedures
- use of sds diagnosis reset procedure
- show data when trouble (displaying data at the time of dtc)
- malfunction code and defective condition
- “c12” (p0335) ckp sensor circuit malfunction
- "c13" (p1750-h/l) or "c17" (p0105-h/l) iap sensor circuit malfunction
- “c14” (p0120-h/l) tp sensor circuit malfunction
- “c15” (p0115-h/l) ect sensor circuit malfunction
- “c21” (p0110-h/l) iat sensor circuit malfunction
- “c23” (p1651-h/l) to sensor circuit malfunction
- "c24" (p0351), "c25" (p0352), "c26" (p0353) or "c27" (p0354) ignition system malfunction
- “c28” (p1655) stv actuator circuit malfunction
- “c29” (p1654-h/l) stp sensor circuit malfunction
- “c31” (p0705) gp switch circuit malfunction
- “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction
- “c40” (p0505-h/l or p0506 and p0507) isc valve circuit malfunction
- “c41” (p0230-h/l) fp relay circuit malfunction
- “c42” (p01650) ig switch circuit malfunction
- “c44” (p0156/p0161) or “c64” (p0130/p0135) ho2 sensor (ho2s)circuit malfunction (for e-02, 19, 24)
- “c46” (p1657-h/l or p1658) excv actuator circuit malfunction
- “c49” (p1768) or “c61” (p1656) pair control solenoid valve circuit malfunction
- “c60” (p0480) cooling fan relay circuit malfunction
- sensors
- iap sensor inspection
- iap sensor removal and installation
- tp sensor inspection
- tp sensor removal and installation
- tps adjustment
- stp sensor inspection
- stp sensor removal and installation
- stp sensor adjustment
- ckp sensor inspection
- ckp sensor removal and installation
- iat sensor inspection
- iat sensor removal and installation
- ect sensor inspection
- ect sensor removal and installation
- to sensor inspection
- to sensor removal and installation
- ho2 sensor inspection (for e-02, 19, 24)
- ho2 sensor removal and installation (for e-02, 19, 24)
06 fuel system and throttle body
- fuel delivery system
- fuel system
- fuel tank removal
- fuel tank installation
- fuel pressure inspection
- fuel pump inspection
- fuel discharge amount inspection
- fuel pump relay inspection
- fuel pump and fuel level gauge removal
- fuel level gauge inspection
- fuel pump disassembly
- fuel mesh filter inspection
- fuel pump and fuel level gauge reassembly and installation
- throttle body
- construction
- air cleaner box removal
- air cleaner box installation
- air cleaner chamber and throttle body removal
- throttle body disassembly
- throttle body cleaning
- inspection
- isc valve inspection
- isc valve removal
- inspection
- isc valve installation
- throttle body reassembly
- air cleaner chamber and throttle body installation
- stp sensor adjustment
- fuel injector removal
- fuel injector inspection
- fuel injector installation
- throttle valve synchronization
- throttle position sensor (tps) setting
07 exhaust system
- excva (exhaust control valve actuator) and excv (exhaust control valve)
- excva and excv removal
- excva inspection
- excv inspection
- cable inspection
- excva and excv installation
- excva adjustment
- exhaust pipe and muffler
- removal
- installation
08 cooling and lubrication system
- engine coolant
- cooling circuit
- cooling circuit inspection
- radiator and water hose
- radiator removal and disassembly
- radiator disassembly
- radiator cap inspection
- radiator inspection and cleaning
- radiator reassembly
- radiator installation
- water hose inspection
- cooling fan
- inspection
- cooling fan relay inspection
- ect sensor
- removal
- inspection
- installation
- thermostat
- removal
- inspection
- installation
- water pump
- removal and disassembly
- inspection
- reassembly and installation
- engine lubrication system chart
09 chassis
- exterior parts
- fastener removal and installation
- front and rear seat
- frame side cover
- rear frame cover
- frame head cover and radiator cover
- front wheel
- construction
- removal
- inspection and disassembly
- reassembly and installation
- front fork
- construction
- removal and disassembly
- inspection
- reassembly
- installation
- steering
- construction
- removal
- inspection and disassembly
- reassembly
- installation
- steering tension adjustment
- handlebars
- construction
- removal
- installation
- rear wheel
- construction
- removal
- disassembly
- inspection and disassembly
- reassembly and installation
- rear suspension
- construction
- removal
- inspection and disassembly
- rear shock absorber disposal
- reassembly
- installation
- suspension setting
- front brake
- construction
- brake pad replacement
- brake fluid replacement
- caliper removal
- caliper disassembly
- caliper inspection
- caliper reassembly
- caliper installation
- brake disc inspection
- master cylinder removal and disassembly
- master cylinder inspection
- master cylinder reassembly
- master cylinder installation
- rear brake
- construction
- brake pad replacement
- brake fluid replacement
- caliper removal
- caliper disassembly
- caliper inspection
- caliper reassembly
- caliper installation
- master cylinder removal
- master cylinder disassembly
- master cylinder inspection
- master cylinder reassembly
- master cylinder installation
- tire and wheel
- tire removal
- inspection
- valve inspection
- tire installation
- balancer weight installation
10 electrical system
- cautions in servicing
- connector
- clamp
- fuse
- semi-conductor equipped part
- battery
- connecting the battery
- wiring procedure
- using the multi-circuit tester
- location of electrical components
- charging system
- troubleshooting
- inspection
- starter system and side-stand/ignition interlock system
- troubleshooting
- starter motor removal
- starter motor disassembly
- starter motor inspection
- starter motor reassembly
- starter relay inspection
- side stand/ignition interlock system parts inspection
- ignition system
- troubleshooting
- inspection
- speedometer and tachometer
- description
- speedometer removal and disassembly
- tachometer removal and disassembly
- inspection
- lamps
- headlight, brake light/taillight, license plate light and turn signal light
- headlight relay inspection
- relays
- turn signal/side-stand relay
- starter relay
- fuel pump relay
- cooling fan relay
- switches inspection
- battery
- specifications
- initial charging
- servicing
- recharging operation
11 servicing information
- troubleshooting
- fi system malfunction code and defective condition
- engine
- radiator (cooling system)
- chassis
- shaft drive
- brakes
- electrical
- battery
- special tools
- tightening torque
- engine
- driveline/axle
- fi system and intake air system
- cooling system
- chassis
- tightening torque chart
- service data
- wiring harness, cable and hose routing
- wiring harness routing
- engine electrical parts lead wire routing
- cable routing
- front brake hose routing
- rear brake hose routing
- throttle body hose routing
- cooling system hose routing
- pair (air supply) system hose routing (for e-03, 28, 33)
- pair (air supply) system hose routing (for the others)
- fuel tank installation
- frame head cover and radiator cover installation
- frame head cover cushion installation
- radiator upper cover cushion installation
- left frame covers installation
- right frame covers installation
- headlight cover installation
- ignition coil installation
- side-stand installation
- rear turn signal light, license light wire routing
- seat lock cable routing
- license light and license plate installation
- brake light/taillight installation
12 emission control information
- emission control systems
- fuel injection system
- crankcase emission control system
- exhaust emission control system (pair system)
- noise emission control system
- evaporative emission control system (only for e-33)
- pair (air supply) system and emission control system inspection
- pair hoses
- pair reed valve
- pair control solenoid valve
- pair (air supply) system hose routing (for e-03, 28, 33)
- pair (air supply) system hose routing (for the others)
- heated oxgen sensor (ho2s) inspection (for e-02, 19, 24)
- evaporative emission control system inspection (only for e-33)
- hoses (evap hose)
- evap canister
- evap canister hose routing (only for e-33)
13 vzr1800 (’07-model)
- specifications
- service data
- tightening torque
- wiring harness routing
14 vzr1800 (’08-model)
- specifications
- service data
- f1 system wiring diagram
- ecm terminal
- fail-safe function
- malfunction code and defective condition
- isc valve reset
- “c44” (p0156) or “c64” (p0130) o2 sensor (o2s) circuit malfunction (for e-02, 19, 24, 51)
- "c49" (p17678) or "c61" (p1656) pair control solenoid valve circuit malfunction
- wiring diagram
- cable routing
15 vzr1800n (’08-model)
- specifications
- service data
- rear wheel
- headlight beam adjustment
- wiring diagram
- wiring harness routing
- front brake hose routing
16 vzr 1800/nk9 (’09-model)
- specifications
- wiring diagram

2010 SERVICE MANUAL
2008 OWNERS MANUAL
2014 OWNERS MANUAL