Suzuki VL1500 '98-'02 Service Manual (99500-39164-01E)

VL1500
99500-39164-01E
VL1500X/Y (’99, 2000-MODELS)
This section describes service data and service specifications which differ from those of the
VL1500W ( ’98-MODEL).
Please refer to the sections 1 through 8 for details which are not given in this section.
CONTENTS
SPECIFICATIONS ............................................................................... 9- 1
SERVICE DATA ................................................................................... 9- 2
BRAKES .............................................................................................. 9-11
FUEL LEVEL GAUGE ......................................................................... 9-11
SPEEDOMETER ................................................................................. 9-12
WIRING DIAGRAM ............................................................................. 9-13
FRONT BRAKE HOSE ROUTING ...................................................... 9-16
REAR BRAKE HOSE ROUTING ........................................................ 9-17
9
9-1 VL1500X/Y (’99, 2000 - MODELS)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .............................................................................. 2 525 mm (99.4 in)
Overall width ................................................................................ 965 mm (38.0 in)
Overall height .............................................................................. 1 165 mm (45.9 in)
Wheelbase ................................................................................... 1 700 mm (66.9 in)
Ground clearance ........................................................................ 145 mm ( 5.7 in)
Seat height .................................................................................. 700 mm (27.6 in)
Dry mass ..................................................................................... 296 kg (652 lbs)
ENGINE
Type ............................................................................................. 4-stroke, Air-cooled with SACS, OHC, Pent-roof
Number of cylinders .................................................................... 2
Bore ............................................................................................. 96 mm (3.780 in)
Stroke .......................................................................................... 101 mm (3.976 in)
Displacement ............................................................................... 1 462 cm3 (89.2 cu. in)
Compression ratio ....................................................................... 8.5 : 1
Carburetor .................................................................................... MIKUNI BDSR36, twin
Air cleaner ................................................................................... Non-woven fabric element
Starter system ............................................................................. Electric
Lubrication system ...................................................................... Wet sump
Idle speed .................................................................................... 950 – 1 050 r/min ..... E-18
900 – 1 100 r/min ..... Others
TRANSMISSION
Clutch ........................................................................................... Wet multi-plate type
Transmission ................................................................................ 5-speed constant mesh
Gearshift pattern ......................................................................... 1-down, 4-up
Primary reduction ratio ................................................................ 1.490 (76/51)
Final reduction ratio ..................................................................... 2.667 (19/19 × 32/12)
Secondary reduction ratio ........................................................... 0.852 (29/34)
Gear ratios, Low ..................................................................... 3.000 (36/12)
2nd ..................................................................... 1.823 (31/17)
3rd ...................................................................... 1.333 (28/21)
4th ...................................................................... 1.041 (25/24)
Top ..................................................................... 0.884 (23/26)
Drive system ........................................................................... Shaft drive
CHASSIS
Front suspension ......................................................................... Telescopic, coil spring, oil damped
Rear suspension ......................................................................... Link type, gas/coil spring, oil damped,
spring pre-load fully adjustable
Front suspension stroke .............................................................. 140 mm (5.5 in)
Rear wheel travel ......................................................................... 118 mm (4.6 in)
Caster .......................................................................................... 32°
Trail .............................................................................................. 138 mm (5.43 in)
Steering angle ............................................................................. 37° (right & left)
Turning radius .............................................................................. 3.1 m (10.2 ft)
Front brake ................................................................................... Disk brake
Rear brake ................................................................................... Disk brake
Front tire size ............................................................................... 150/80-16 71H, tubeless
Rear tire size ............................................................................... 180/70-15 M/C 76H, tubeless
ELECTRICAL
Ignition type ................................................................................. Electronic ignition (Transistorized)
Ignition timing .............................................................................. 2° B.T.D.C. at 1 000 r/min
Spark plug ................................................................................... NGK DPR7EA-9 or DENSO X22EPR-U9
Battery ......................................................................................... 12V 50.4 kC (14Ah)/10 HR
Generator ..................................................................................... Three-phase A.C. generator
Main fuse ..................................................................................... 30 A
Fuse ............................................................................................. 15/15/15/10/10 A
Headlight ...................................................................................... 12 V 60/55 W (H4)
Position/Parking light ................................................................... 12 V 4 W ..... Except E-03, 24, 28, 33
Brake light/Taillight ...................................................................... 12 V 21/5 W
Turn signal light ........................................................................... 12 V 21/5 W ..... E-03, 28, 33
12 V 21 W ..... Others
Speedometer light ....................................................................... 12 V 0.84 W
Fuel level warning light ................................................................ 12 V 1.7 W
Turn signal indicator light ............................................................ 12 V 1.7 W
Neutral indicator light .................................................................. 12 V 1.7 W
High beam indicator light ............................................................ 12 V 1.7 W
Oil pressure indicator light .......................................................... LED
CAPACITIES
Fuel tank ...................................................................................... 15.5 L (4.1/3.4 US/Imp gal) .................... X-MODEL
* 15.0 L (4.0/3.3 US/Imp gal) .................... Y-MODEL
Engine oil,oil change ................................................................... 3 700 ml (3.9/3.3 US/Imp qt)
with filter change ........................................................ 4 300 ml (4.5/3.8 US/Imp qt)
overhaul ...................................................................... 5 000 ml (5.3/4.4 US/Imp qt)
Final gear oil ................................................................................ 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)
Front fork oil (each leg) ............................................................... 439 ml (14.8/15.5 US/Imp oz)
VL1500X/Y (’99, 2000 - MODELS) 9-2
SERVICE DATA
VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diam. 33 ———
IN.
(1.3)
40 ———
EX.
(1.6)
Lash-adjuster plunger stroke 0 – 0.5 ———
(0 – 0.02)
Valve guide to valve stem 0.010 – 0.037 ———
IN.
clearance (0.0004 – 0.0015)
0.040 – 0.070 ———
EX.
(0.0016 – 0.0028)
Valve stem deflection 0.35
IN. & EX. ———
(0.014)
Valve guide I.D. 5.500 – 5.512 ———
IN.
(0.2165 – 0.2170)
7.000 – 7.015 ———
EX.
(0.2756 – 0.2762)
Valve stem O.D. 5.475 – 5.490 ———
IN.
(0.2156 – 0.2161)
6.945 – 6.960 ———
EX.
(0.2734 – 0.2740)
Valve stem runout 0.05
IN. & EX. ———
(0.002)
Valve head thickness 0.5
IN. & EX. ———
(0.02)
Valve stem end length 2.5
IN. ———
(0.10)
2.2
EX. ———
(0.09)
Valve seat width 0.9 – 1.1 ———
IN.
(0.035 – 0.043)
1.0 – 1.2 ———
EX.
(0.039 – 0.047)
Valve head radial runout 0.03
IN. & EX. ———
(0.001)
Valve spring free length 35.0
INNER ———
(INTAKE) (1.38)
37.8
OUTER ———
(1.49)
———
(EXHAUST) (1.60)
Valve spring tension (INTAKE) 5.3 – 6.5 kgf
INNER (11.68 – 14.33 Ibs) ———
at length 28.0 mm (1.10 in)
14.0 – 14.2 kgf
OUTER (30.86 – 31.31 Ibs) ———
Valve spring tension (EXHAUST) 20.3 – 23.3 kgf
(44.75 – 51.37 Ibs) ———
9-3 VL1500X/Y (’99, 2000 - MODELS)
CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height 35.680 – 35.730 35.38
IN.
(1.4047 – 1.4067) (1.393)
36.880 – 36.930 36.58
EX.
(1.4521 – 1.4537) (1.440)
Camshaft journal oil clearance 0.032 – 0.066 0.150
IN. & EX.
(0.0013 – 0.0026) (0.0060)
Camshaft journal holder I.D. Front head right side, 20.012 – 20.025 ———
rear head left side (0.7879 – 0.7884)
Front head left side, 25.012 – 25.025 ———
rear head right side (0.9847 – 0.9852)
Camshaft journal O.D. Front head right side, 19.959 – 19.980 ———
Camshaft runout ——— 0.10
Front & Rear
(0.004)
Rocker arm I.D. 14.000 – 14.018 ———
IN.
(0.5511 – 0.5519)
16.000 – 16.018 ———
EX.
(0.6299 – 0.6303)
Rocker arm shaft O.D. 13.966 – 13.984 ———
IN.
(0.5498 – 0.5506)
15.966 – 15.984 ———
EX.
(0.6286 – 0.6293)
Cylinder head distortion ——— 0.05
(0.002)
Cylinder head cover distortion ——— 0.05
(0.002)
CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Campression pressure 1 000 – 1 400 kPa 800 kPa
(Automatic de-compression 10 – 14 kgf/cm2 8 kgf/cm2
actuated) ( 142 – 199 psi ) ( 144 psi )
Campression pressure difference 200 kPa
——— 2 kgf/cm2
( 28 psi )
Piston to cylinder clearance 0.02 – 0.03 0.120
(0.0008 – 0.0012) (0.0047)
Cylinder bore 96.000 – 96.015 Nicks or
(3.7795 – 3.7801) Scratches
Piston diam. 95.975 – 95.990
95.88
(3.7785 – 3.7791)
(37.7748)
Measure at 16 mm (0.6 in) from the skirt end.
Cylinder distortion ——— 0.05
(0.002)
Piston ring free end gap 13.5 10.8
1st T Approx.
(0.53) (0.43)
14.0 11.2
2nd T Approx.
(0.55) (0.44)
VL1500X/Y (’99, 2000 - MODELS) 9-4
ITEM STANDARD LIMIT

Piston ring end gap 0.30 – 0.45 0.70
1st
(0.012 – 0.018) (0.028)
0.45 – 0.60 1.00
2nd
(0.018 – 0.024) (0.039)
Piston ring to groove clearance ——— 0.180
1st
(0.007)
——— 0.150
2nd
(0.006)
Piston ring groove width 1.210 – 1.230 ———
1st
(0.0476 – 0.0484)
1.510 – 1.530 ———
2nd
(0.0594 – 0.0602)
2.810 – 2.830 ———
Oil
(0.1106 – 0.1114)
Piston ring thickness 1.160 – 1.175 ———
1st
(0.0457 – 0.0463)
1.470 – 1.490 ———
2nd
(0.0579 – 0.0587)
Piston pin bore 23.002 – 23.008 23.030
(0.9056 – 0.9058) (0.9067)
Piston pin O.D. 22.992 – 23.000 22.980
(0.9052 – 0.9055) (0.9047)
CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 23.015 – 23.023 23.040
(0.9061 – 0.9064) (0.9071)
Conrod big end side clearance 0.10 – 0.20 0.3
(0.004 – 0.008) (0.012)
Conrod big end width 21.95 – 22.00 ———
(0.864 – 0.866)
Crank pin width 22.10 – 22.15 ———
(0.870 – 0.872)
Conrod big end oil clearance 0.024 – 0.042 0.080
(0.0009 – 0.0017) (0.0031)
Crank pin O.D. 49.982 – 50.000 ———
(1.9678 – 1.9685)
Crankshaft journal oil clearance 0.020 – 0.050 0.080
(0.0008 – 0.0020) (0.0031)
Crankshaft journal O.D. 51.965 – 51.980 ———
(2.0459 – 2.0465)
Crankshaft journal I.D. 52.000 – 52.015 ———
(2.0472 – 2.0478)
Crankshaft thrust bearing 1.925 – 2.175 ———
thickness (0.0758 – 0.0856)
Crankshaft thrust clearance 0.05 – 0.10 ———
(0.002 – 0.004)
Crankshaft runout ——— 0.05
(0.002)
9-5 VL1500X/Y (’99, 2000 - MODELS)
OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1.154 (76/51 × 31/40) ———
Oil pressure (at 60°C, 140°F) Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi) ———
at 3 000 r/min.
CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Drive plate thickness 2.90 – 3.10 2.60
(0.114 – 0.122) (0.102)
Drive plate claw width 15.6 – 15.8 14.8
(0.614 – 0.622) (0.583)
Driven plate distortion ——— 0.10
(0.004)
Clutch spring free length ——— 30.9
(1.22)
Clutch master cylinder bore 14.000 – 14.043 ———
(0.5512 – 0.5529)
Clutch master cylinder piston 13.957 – 13.984 ———
diam. (0.5495 – 0.5506)
Clutch release cylinder bore 33.600 – 33.662 ———
(1.3228 – 1.3253)
Clutch release cylinder piston 33.550 – 33.575 ———
diam. (1.3209 – 1.3218)
TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 1.490 (76/51) ———
Secondary reduction ratio 0.852 (29/34) ———
Final reduction ratio 2.667 (19/19 × 32/12) ———
Gear ratios Low 3.000 (36/12) ———
2nd 1.823 (31/17) ———
3rd 1.333 (28/21) ———
4th 1.041 (25/24) ———
Top 0.884 (23/26) ———
Shift fork to groove clearance 0.1 – 0.3 0.5
(0.004 – 0.012) (0.020)
Shift fork groove width 5.50 – 5.60 ———
(0.217 – 0.220)
Shift fork thickness 5.30 – 5.40 ———
(0.209 – 0.213)
Damper spring free length ——— 73.6
(2.90)
Gearshift lever height 82 ———
(3.23)
VL1500X/Y (’99, 2000 - MODELS) 9-6
SHAFT DRIVE Unit: mm (in)

ITEM STANDARD LIMIT
Secondary bevel gear backlash 0.03 – 0.15
(0.001 – 0.006) ———
Final bevel gear backlash 0.03 – 0.64
(0.001 – 0.025) ———
CARBURETOR
STANDARD
ITEM
E-02, 04, 25, 34 E-03, 28
Carburetor type BDSR36 ←
Bore size 36.5 mm ←
I.D. No. 10F0 10F1
Idle r/min. 1 000 ± 100 r/min. ←
Float height 7.0 ± 0.5 mm ←
(0.28 ± 0.02 in)
Main jet (M.J.) F: #112.5 F: #
R: #110 R: #
Jet needle (J.N.) F: 5D94-56-3 F: 5D95-56
R: 5E8-56-3 R: 5E9-56
Needle jet (N.J.) P-0
Throttle valve (Th.V.) #90 ←
Pilot jet (P.J.) #32.5 #
Pilot screw (P.S.) PRE-SET
F: 2 turns back PRE-SET
(R: 2 turns back )
Throttle cable play 2.0 – 4.0 mm ←
(0.08 – 0.16 in)
CARBURETOR
STANDARD
ITEM
E-17, 22, 24 E-18
I.D. No. 10F2 10F3
Idle r/min. 1 000 ± 100 r/min. 1 000 ± 50 r/min.
Float height 7.0 ± 0.5 mm ←
(0.28 ± 0.02 in)
Main jet (M.J.) F: #112.5 ←
R: #110
Jet needle (J.N.) F: 5D94-56-3 ←
R: 5E8-56-3
Needle jet (N.J.) P-0 ←
Throttle valve (Th.V.) #90 ←
Pilot jet (P.J.) #32.5 ←
Pilot screw (P.S.) PRE-SET PRE-SET
F: 2 turns back F: 2 1/2 turns back
(R: 2 turns back ) ( R: 2 5/8 turns back )
(0.08 – 0.16 in)
9-7 VL1500X/Y (’99, 2000 - MODELS)
CARBURETOR
STANDARD
ITEM
E-33 P-37
I.D. No. 10F7 10F6
Idle r/min. 1 000 ± 100 r/min. ←
Float height 7.0 ± 0.5 mm
←
(0.28 ± 0.02 in)
Main jet (M.J.) F: # F: #112.5
R: # R: #110
Jet needle (J.N.) F: 5D95-56 F: 5D94-56-3
R: 5E9-56 R: 5E8-56-3
Needle jet (N.J.) P-0
Throttle valve (Th.V.) # 90 ←
Pilot jet (P.J.) # #32.5
PRE-SET F: 2 turns back
( R: 2 turns back )
(0.08 – 0.16 in)
ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 2° B.T.D.C. at 1 000 r/min.
Firing order R.F
Spark plug NGK: DPR7EA-9
Type
DENSO: X22EPR-U9
0.8 – 0.9
Gap
(0.031 – 0.035)
Spark performance Over 8 (0.3) at 1 atm.
Signal coil resistance 178 – 242 Ω Bl – G
Signal coil peak voltage More than 2.4 V
Ignition coil resistance Primary 1–7Ω tap – tap
Plug cap –
Secondary 18 – 28 kΩ
tap
Ignition coil primary peak voltage Front More than 190 V B/Y – Ground
Rear More than 200 V W – Ground
Generator Max. output Approx. 340 W at 5 000 r/min.
Generator no-load voltage More than 80 V (AC) at 5 000 r/min.
(when engine is cold)
Regulated voltage 13.5 – 15.0 V at 5 000 r/min.
Starter relay resistance 3–6Ω
De-comp. solenoid resistance 0.1 – 1.0 Ω
Fuel pump resistance 1 – 2.5 Ω
Fuel pump discharge amount More than 600 ml (1.27 US qt)/minute
VL1500X/Y (’99, 2000 - MODELS) 9-8

Battery Type designation FTH16-BS-1
Voltage 12 V
Capacity 50.4 kC (14 Ah)/10HR
Standard
1.320 at 20°C (68°F)
electrolyte S.G.
Fuse size HI 15 A
Headlight
LO 15 A
Signal 15 A
Ignition 10 A
Main 30 A
Power source 10 A
WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 28, 33 E-24 Others
Headlight HI 60 ← ←
LO 55 ← ←
Position light 4
Brake light / Taillight 21/5 ← ←
Turn signal light 21 ← ←
Running light 5
Speedometer light 0.84 ← ←
Turn signal indicator light 1.7 ← ←
High beam indicator light 1.7 ← ←
Neutral indicator light 1.7 ← ←
Fuel level warning light 1.7 ← ←
BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 98 ———
(3.86)
Brake disc thickness 5.8 – 6.2 5.5
Front
(0.228 – 0.244) (0.22)
6.6 – 7.0 6.3
Rear
(0.260 – 0.276) (0.25)
Brake disc runout ——— 0.30
(0.012)
Master cylinder bore 12.700 – 12.743 ———
Front
(0.5000 – 0.5017)
12.700 – 12.743 ———
Rear
(0.5000 – 0.5017)
Master cylinder piston diam. 12.657 – 12.684 ———
Front
(0.4983 – 0.4994)
12.657 – 12.684 ———
Rear
(0.4983 – 0.4994)
9-9 VL1500X/Y (’99, 2000 - MODELS)
ITEM STANDARD LIMIT

Brake caliper cylinder bore 45.000 – 45.076 ———
Front
(1.7717 – 1.7746)
42.850 – 42.926 ———
Rear
(1.6870 – 1.6900)
Brake caliper piston diam. 44.930 – 44.980 ———
Front
(1.7689 – 1.7709)
42.770 – 42.820 ———
Rear
(1.6839 – 1.6858)
Wheel rim runout ——— 2.0
Axial
(0.08)
——— 2.0
Radial
(0.08)
Wheel axle runout ——— 0.25
Front
(0.010)
——— 0.25
Rear
(0.010)
Wheel rim size Front 16 × MT3.50 ———
Rear 15M/C × MT5.00 ———
Tire size Front 150/80-16 71H ———
Rear 180/70-15M/C 76H ———
Tire tread depth ——— 1.6
Front
(0.06)
——— 2.0
Rear
(0.08)
SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 140 ———
(5.5)
Front fork spring free length 585 573
(23.03) (22.56)
Front fork oil level 169.0 ———
(6.65)
Rear shock absorber spring 222.0 ———
set length (8.74)
Rear wheel travel 118 ———
(4.6)
TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa 2
kgf/cm psi kPa kgf/cm2 psi
FRONT 200 2.00 29 200 2.00 29
REAR 250 2.50 36 250 2.50 36
VL1500X/Y (’99, 2000 - MODELS) 9-10
FUEL + OIL
Fuel type Use only unleaded gasoline of at least 87 pump
octane ( R +2 M ) or 91 octane or higher rated by the
research method. Gasoline containing MTBE (Me-
thyl Tertiary Butyl Ether), less than 10% ethanol, E-03, 33
or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Use only unleaded gasoline of at least 87 pump
octane ( R +2 M method) or 91 octane or higher rated E-28
by the Research Method.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended. The others
Fuel tank 15.5 L (4.1/3.4 US/Imp gal) X-MODEL

*15.0 L (4.0/3.3 US/Imp gal) Y-MODEL
Engine oil type SAE 10W/40, API SF or SG
Engine oil capacity 3 700 ml
Change
(3.9/3.3 US/lmp qt)
Filter 4 300 ml
change (4.5/3.8 US/lmp qt)
5 000 ml
Overhaul
(5.3/4.4 US/lmp qt)
Fuel fork oil type SUZUKI FORK OIL SS-08 (#10)
or equivalent fork oil
Fuel fork oil capacity (each leg) 439 ml
(14.8/15.5 US/lmp oz)
Bevel gear oil type Hypoid Gear oil #90 API GL-5
Bevel gear oil capacity 200 – 220 ml
Final
(6.8/7.0 – 7.4/7.7 US/lmp oz)
Brake fluid type DOT 4
9-11 VL1500X/Y (’99, 2000 - MODELS)
BRAKES FRONT
FRONT BRAKE CALIPER Left

• When reassembling the brake pad, install the pad shims as brake pad
shown.
Shim
Right
brake pad
REAR BRAKE CALIPER

• When reassembling the brake caliper, install the insulator 1
into the right side piston.
1
Wheel
side
FUEL LEVEL GAUGE

INSPECTION
63.3 mm
• Remove the fuel level gauge as the same manner of the W-
model.
159.1 mm
• Measure the resistance at each fuel level gauge float posi- 103.5
mm
tion.
• If the resistance is incorrect, replace the fuel level gauge with
a new one.
NOTE:
The following table shows the relation between the float position
of the fuel level gauge sending unit and the resistance.
Float position Resistance

63.3 mm (2.49 in) 1–5Ω
103.5 mm (4.07 in) 28.5 – 36.5 Ω
159.1 mm (6.26 in) 103 – 117 Ω
VL1500X/Y (’99, 2000 - MODELS) 9-12
SPEEDOMETER
FUEL LEVEL INDICATOR LIGHT AND
FUEL LEVEL METER INSPECTION
To test the fuel level indicator light A and the fuel level meter B,
perform the following procedure:
If the tests defect fuel level indicator malfunction or meter mal-
function, replace the speedometer.
B
Test 1.
• Check if the fuel level indicator light comes on and the fuel
level meter displays all segments for three seconds when ig-
nition switch is turned on.
Test 2.
• Romove the seat. Main wiring
harness
• Disconnect the fuel level gauge lead wire coupler.
• Connect each resistor between the Y/B and B/W lead wire To fuel level
gauge
coming from main wiring harness.
• Turn on the ignition switch and wait for 13 seconds.
• Check if the fuel level indicator light and meter function as
shown below. Resistor
Less than More than

Resistance 20 – 34 Ω 38 – 58 Ω 62 – 87 Ω 91 – 97 Ω
16 Ω 103 Ω
Flicker
Fuel level
meter
Fuel level
indicator
light OFF OFF OFF OFF ON ON
9-13
SPEEDOMETER LIGHTING AUTOMATIC

N : NEUTRAL INDICATOR LIGHT FUEL LEVEL DE-COMPRESSION
SWITCH ENGINE STOP STARTER FRONT BRAKE
O : OIL PRESSURE INDICATOR LIGHT SWITCH BUTTON LIGHT SWITCH GAUGE SOLENOID
OFF
H : HIGHT BEAM INDICATOR LIGHT T H O N S OFF • OFF
T : TURN SIGNAL INDICATOR LIGHT SIDE-STAND
ON RUN PUSH ON
SWITCH
REAR BRAKE FUEL
IGNITION COIL LIGHT SWITCH PUMP PUSH
REAR FRONT FREE
ON AUTOMATIC
SPEED SENSOR THROTTLE OFF
POSITION DE-COMPRESSION IGNITOR
Gr
B/R
Y/G
O/R
O/B
Y/W
O/W
B/Bl
O/Bl
SENSOR RELAY
O
G
W
W
Y/B
W/B
B/W
B/W
B/W
Br/B
P
Y
P
B
B
R
O
Gr
Gr
Lg
Y/B
O/Y
O/Y
Y/G
O/B
O/G
O/G
O/G
Y/W
B/W
B/W
B/W
W/B
Bl/B
O/W
R
R
R
G
G
W
W
W
W
Bl
Bl
Br
Br
B/Y
Y/B
Y/B
B/Y
R/B
Y/G
O/Y
G/R
O/R
G/R
O/G
W/B
B/W
B/W
B/W
B/W
B/W
O/W
O/W
B/Bl
O/W
B/Bl
G/Bl
B/Br
22, 25, 34 AND P-37
FOR E-02, 04, 17, 18
WIRING DIAGRAM
VL1500X/Y (’99, 2000 - MODELS)
FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
B Lg Lg
B/W B/W B/W
Gr
BRAKE LIGHT/
HEADLIGHT Lg TAILLIGHT
Y W/B W/B
B/W B/W B/W
W Br Gr
B
FRONT TURN SIGNAL LIGHT (L)
B B
B/W B/W
Gr B/W
B
Br Br
B/W B/W
REAR TURN SIGNAL LIGHT (L)
POSITION LIGHT
WIRE COLORS
B ....... Black
Bl . . . . . . . Blue
Br . . . . . . . Brown
G ....... Green
O/G
B/Bl
Gr . . . . . . Gray
Lbl . . . . . . Light blue
Lg . . . . . . Light green
O ....... Orange
R
Br
B/Br
P ....... Pink
Y
Y
Y
B
R
B
B
B
B
B
B
B
R
O
O
O
G
G
W
W
W
Bl
Bl
R ....... Red
Br
Br
Gr
Lg
Lbl
Lbl
Y/B
Y/G
R/B
O/Y
O/Y
O/R
O/B
O/G
O/G
Y/W
B/W
B/W
B/W
B/W
B/Bl
Bl/B
B
O/Bl
G/Bl
O/Bl
B/Bl
W. . . . . . . White
Y ....... Yellow
– + B/Bl . . . . . Black with Blue tracer
R
Y/G
O/W
B/Br . . . . . Black with Brown tracer

B/R . . . . . Black with Red tracer
B
+–
Lg
Lbl
MAP SENSOR
B/Y
B/Y
O/R
Y/W
B/W
B/Bl
B/W . . . . . Black with White tracer
B
B
B
B
B
B
Bl
Bl
3 4 5
R/B
B/R
B/W
B/W
G/Bl
B/Y . . . . . Black with Yellow tracer
B
B
B/Bl
B/Bl
P Bl/B . . . . . Blue with Black tracer
LOCK – + Br/B . . . . . Brown with Black tracer
OFF 1 2
ON
G/Bl . . . . . Green with Blue tracer
• L HI FREE 1 G/R . . . . . Green with Red tracer
PUSH PUSH PUSH LO • IGNITION SWITCH NEUTRAL BATTERY O/B . . . . . Orange with Black tracer
R GENERATOR REGULATOR/
HORN PASSING DIMMER CLUTCH INDICATOR FUSE BOX (SIGNAL RECTIFIER O/Bl . . . . . Orange with Blue tracer
HORN LIGHT SWITCH STARTER STARTER RELAY O/G . . . . . Orange with Green tracer
BUTTON TURN SIGNAL LIGHT SWITCH LEVER GENERATOR) MOTOR
LIGHT SWITCH SWITCH POSITION O/R . . . . . Orange with Red tracer
ON 1 : HEAD LIGHT (HI) 10A 1 : MAIN FUSE 30A
SWITCH OFF
O/W. . . . . . Orange with White tracer
2 : HEAD LIGHT (LOW) 10A
O/Y . . . . . Orange with Yellow tracer
3 : IGNITION 10A
R/B . . . . . Red with Black tracer
4 : SIGNAL 15A
OIL PRESSURE SWITCH Y/B . . . . . Yellow with Black tracer
5 : POWER SOURCE 10A
Y/G . . . . . Yellow with Green tracer
Y/W . . . . . Yellow with White tracer
W/B . . . . . White with Black tracer
SPEEDOMETER AUTOMATIC
N : NEUTRAL INDICATOR LIGHT ENGINE STOP STARTER FRONT BRAKE FUEL LEVEL DE-COMPRESSION
H : HIGHT BEAM INDICATOR LIGHT T H O N OFF • OFF
RUN PUSH ON
SWITCH
FOR E-24
REAR BRAKE FUEL

REAR FRONT FREE
ON AUTOMATIC
B/R
Y/G
O/R
O/B
O/W
B/Bl
O/Bl
SENSOR RELAY
O
G
W
W
Y/B
W/B
B/W
B/W
B/W
Br/B
P
Y
P
B
B
R
O
Gr
Gr
Lg
Y/B
O/Y
O/Y
Y/G
O/B
O/G
O/G
O/G
Y/W
B/W
B/W
B/W
W/B
Bl/B
O/W
R
R
R
G
G
W
W
W
W
Bl
Bl
Br
Br
B/Y
Y/B
Y/B
B/Y
R/B
Y/G
O/Y
G/R
O/R
G/R
O/G
W/B
B/W
B/W
B/W
B/W
B/W
O/W
O/W
B/Bl
O/W
B/Bl
G/Bl
B/Br
B Lg Lg
B/W B/W B/W
Gr
BRAKE LIGHT/
Y W/B W/B
B/W B/W B/W
W Br Gr
B
B B
B/W B/W
Gr B/W
B
Br
B/W
POSITION LIGHT
WIRE COLORS
B ....... Black
Bl . . . . . . . Blue
Br . . . . . . . Brown
G ....... Green
O/G
B/Bl
Gr . . . . . . Gray
O ....... Orange
R
Br
B/Br
P ....... Pink
Y
Y
Y
B
R
B
B
B
B
B
B
B
R
O
O
O
G
G
W
W
W
Bl
Bl
R ....... Red
Br
Br
Gr
Lg
Lbl
Lbl
Y/B
Y/G
R/B
O/Y
O/Y
O/R
O/B
O/G
O/G
Y/W
B/W
B/W
B/W
B/W
B/Bl
Bl/B
B
O/Bl
G/Bl
O/Bl
B/Bl
W. . . . . . . White
Y ....... Yellow
R
Y/G
O/W

B
+–
Lg
Lbl
MAP SENSOR
B/Y
B/Y
O/R
Y/W
B/W
B/Bl
B
B
B
B
B
B
Bl
Bl
3 4 5
R/B
B/R
B/W
B/W
G/Bl
B
B
B/Bl
B/Bl
Bl/B . . . . . Blue with Black tracer
OFF 1 2
ON
PUSH PUSH PUSH LO • IGNITION SWITCH NEUTRAL BATTERY O/B . . . . . Orange with Black tracer
HORN PASSING DIMMER CLUTCH INDICATOR FUSE BOX (SIGNAL RECTIFIER O/Bl . . . . . Orange with Blue tracer
BUTTON TURN SIGNAL LIGHT SWITCH LEVER GENERATOR) MOTOR
LIGHT SWITCH SWITCH POSITION O/R . . . . . Orange with Red tracer
SWITCH OFF
3 : IGNITION 10A
4 : SIGNAL 15A
VL1500X/Y (’99, 2000 - MODELS)

9-14
9-15
SPEEDOMETER AUTOMATIC
N : NEUTRAL INDICATOR LIGHT ENGINE STOP STARTER FRONT BRAKE FUEL LEVEL DE-COMPRESSION
H : HIGHT BEAM INDICATOR LIGHT T H O N OFF • OFF
RUN PUSH ON
SWITCH
REAR BRAKE FUEL
REAR FRONT FREE
ON AUTOMATIC
B/R
Y/G
O/R
O/B
O/W
B/Bl
O/Bl
SENSOR RELAY
O
G
W
W
Y/B
W/B
B/W
B/W
B/W
Br/B
P
Y
P
B
B
R
O
Gr
Gr
Lg
Y/B
O/Y
O/Y
Y/G
O/B
O/G
O/G
O/G
Y/W
B/W
B/W
B/W
W/B
Bl/B
O/W
R
R
R
G
G
W
W
W
W
Bl
Bl
Br
Br
B/Y
Y/B
Y/B
B/Y
R/B
Y/G
O/Y
G/R
O/R
G/R
O/G
W/B
B/W
B/W
B/W
B/W
B/W
O/W
O/W
B/Bl
O/W
B/Bl
G/Bl
B/Br
FOR E-03, 28 AND 33
VL1500X/Y (’99, 2000 - MODELS)
B Lg Lg
B/W B/W B/W
Gr Gr
BRAKE LIGHT/
Y W/B W/B
B/W B/W B/W
W Br Gr
B
B B
B/W B/W
Gr Gr B/W
B
Br
B/W
POSITION LIGHT
WIRE COLORS
B ....... Black
Bl . . . . . . . Blue
Br . . . . . . . Brown
G ....... Green
O/G
B/Bl
Gr . . . . . . Gray
O ....... Orange
R
Br
B/Br
P ....... Pink
Y
Y
Y
B
R
B
B
B
B
B
B
B
R
O
O
O
G
G
W
W
W
Bl
Bl
R ....... Red
Br
Br
Gr
Lg
Lbl
Lbl
Y/B
Y/G
R/B
O/Y
O/Y
O/R
O/B
O/G
O/G
Y/W
B/W
B/W
B/W
B/W
B/Bl
Bl/B
B
O/Bl
G/Bl
O/Bl
B/Bl
W. . . . . . . White
Y ....... Yellow
R
Y/G
O/W

B
+–
Lg
Lbl
MAP SENSOR
B/Y
B/Y
Y/W
B/W
B/Bl
B
B
B
B
B
B
Bl
Bl
3 4 5
B/R
B/W
B/W
B
B
B/Bl
B/Bl
P Bl/B . . . . . Blue with Black tracer
OFF 1 2
ON
PUSH PUSH LO • IGNITION SWITCH NEUTRAL BATTERY O/B . . . . . Orange with Black tracer
HORN DIMMER CLUTCH INDICATOR FUSE BOX (SIGNAL RECTIFIER O/Bl . . . . . Orange with Blue tracer
BUTTON TURN SIGNAL SWITCH LEVER GENERATOR) MOTOR
LIGHT SWITCH POSITION O/R . . . . . Orange with Red tracer
SWITCH OFF
3 : IGNITION 10A
4 : SIGNAL 15A
VL1500X/Y (’99, 2000 - MODELS) 9-16
FRONT BRAKE HOSE ROUTING
Master cylinder
Clamp the brake hose to the

Master cylinder 90° front fork lower bracket firmly.
28°
Turn signal light

bracket
Brake hose
Throttle cable
Clamp the
brake hose firmly.
After touching the brake hose clamp

stopper to the front fork, tighten the bolt.
Clamp the brake

hose firmly.
Brake caliper
9-17
21˚
90˚
VL1500X/Y (’99, 2000 - MODELS)
Brake hose must be passed

over the brake support boss After touching the
and caliper bracket. brake hose union to
the stopper, tighten
the union bolt to the
specified torque.
Brake caliper Reservoir tank
Clamp
REAR BRAKE HOSE ROUTING (Y-MODEL)
Clamp
Brake hose Master cylinder
Clamp
Clamp
After touching the clamp stopper
to the frame, tighten the bolt.
VL1500K1 (’01-MODEL)
This chapter describes service data, service specifications and servicing procedures which differ
from those of the VL1500Y ( ’00-model).
CONTENTS
SPECIFICATIONS ............................................................................... 10- 1
SERVICE DATA ................................................................................... 10- 2
ENGINE INSTALLATION .................................................................... 10-10
PAIR (AIR SUPPLY) SYSTEM DIAGRAM .......................................... 10-11
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................... 10-12
PAIR (AIR SUPPLY) SYSTEM INSPECTION ..................................... 10-13
WIRE HARNESS ROUTING ............................................................... 10-14
NOTE:
Any difference between the VL1500Y (’00-model) and VL1500K1 (’01-model) in specifications
and service data are clearly indicated with an asterisk (*).
10
10-1 VL1500K1 (’01 - MODEL)
SPECIFICATIONS
Overall length ........................................................................... 2 525 mm (99.4 in)
Overall width ............................................................................. 965 mm (38.0 in)
Overall height ........................................................................... 1 165 mm (45.9 in)
Wheelbase ................................................................................ 1 700 mm (66.9 in)
Ground clearance ..................................................................... 145 mm ( 5.7 in)
Seat height ............................................................................... 700 mm (27.6 in)
Dry mass .................................................................................. 296 kg (652 lbs)
ENGINE
Type .......................................................................................... 4-stroke, Air-cooled, OHC
Number of cylinders ................................................................. 2
Bore .......................................................................................... 96 mm (3.780 in)
Stroke ....................................................................................... 101 mm (3.976 in)
Displacement ............................................................................ 1 462 cm3 (89.2 cu. in)
Compression ratio .................................................................... 8.5 : 1
Carburetor ................................................................................ MIKUNI BDSR36, twin
Air cleaner ................................................................................ Non-woven fabric element
Starter system .......................................................................... Electric
Lubrication system ................................................................... Wet sump
Idle speed ................................................................................. 1 000 ± 100 r/min
TRANSMISSION
Clutch ........................................................................................ Wet multi-plate type
Transmission ............................................................................ 5-speed constant mesh
Gearshift pattern ...................................................................... 1-down, 4-up
Primary reduction ratio ............................................................. 1.490 (76/51)
Final reduction ratio .................................................................. 2.666 (19/19 × 32/12)
Secondary reduction ratio ........................................................ 0.852 (29/34)
Gear ratios, Low ...................................................................... 3.000 (36/12)
2nd ...................................................................... 1.823 (31/17)
3rd ....................................................................... 1.333 (28/21)
4th ....................................................................... 1.041 (25/24)
Top ....................................................................... 0.884 (23/26)
Drive system ............................................................................. Shaft drive
CHASSIS
Front suspension ...................................................................... Telescopic, coil spring, oil damped
Rear suspension ...................................................................... Link type, coil spring, oil damped, spring pre-load fully adjustable
Front suspension stroke ........................................................... 140 mm (5.5 in)
Rear wheel travel ..................................................................... 118 mm (4.6 in)
Caster ....................................................................................... 32°
Trail ........................................................................................... 138 mm (5.43 in)
Steering angle .......................................................................... 39° (right & left)
Turning radius ........................................................................... 3.1 m (10.2 ft)
Front brake ............................................................................... Disk brake
Rear brake ................................................................................ Disk brake
Front tire size ............................................................................ 150/80-16 71H, tubeless
Rear tire size ............................................................................ 180/70-15 M/C 76H, tubeless
ELECTRICAL
Ignition type .............................................................................. Electronic ignition (Transistorized)
Ignition timing ........................................................................... 2° B.T.D.C. at 1 000 r/min
Spark plug ................................................................................ NGK DPR7EA-9 or DENSO X22EPR-U9
Battery ...................................................................................... 12V 50.4 kC (14Ah)/10 HR
Generator ................................................................................. Three-phase A.C. generator
Main fuse .................................................................................. 30A
Fuse .......................................................................................... 15/15/15/10/10A
Headlight .................................................................................. 12V 60/55W (H4)
Position/Parking light ................................................................ 12V 4W ..... Except E-03, 24, 28, 33
Brake light/Taillight ................................................................... 12V 21/5W
Turn signal light ........................................................................ 12V 21/5W ..... E-03, 28, 33
12V 21W ..... Others
Speedometer light .................................................................... 12V 0.84W × 2
Fuel level warning light ............................................................. 12V 1.7W
Turn signal indicator light ......................................................... 12V 1.7W
Neutral indicator light ............................................................... 12V 1.7W
High beam indicator light ......................................................... 12V 1.7W
Oil pressure indicator light ....................................................... LED
CAPACITIES
Fuel tank ................................................................................... 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change .............................................................. 3 700 ml (3.9/3.3 US/Imp qt)
with filter change .................................................... 4 300 ml (4.5/3.8 US/Imp qt)
overhaul ................................................................. 5 000 ml (5.3/4.4 US/Imp qt)
Final gear oil ............................................................................. 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)
Front fork oil (each leg) ............................................................ 439 ml (14.8/15.5 US/Imp oz)
VL1500K1 (’01 - MODEL) 10-2
SERVICE DATA
ITEM STANDARD LIMIT
Valve diam. 33
IN. (1.3) ———
40
EX. (1.6) ———
Lash-adjuster plunger stroke 0 – 0.5
(0 – 0.02) ———
Valve guide to valve stem 0.010 – 0.037
clearance IN. (0.0004 – 0.0015) ———
0.040 – 0.070
EX. (0.0016 – 0.0028) ———
IN. & EX. ———
(0.014)
Valve guide I.D. 5.500 – 5.512
IN. (0.2165 – 0.2170) ———
7.000 – 7.015
EX. (0.2756 – 0.2762) ———
Valve stem O.D. 5.475 – 5.490
IN. (0.2156 – 0.2161) ———
6.945 – 6.960
EX. (0.2734 – 0.2740) ———
IN. & EX. ——— (0.002)
IN. & EX. ——— (0.02)
IN. ——— (0.10)
2.2
EX. ——— (0.09)
Valve seat width 0.9 – 1.1
IN. (0.035 – 0.043) ———
1.0 – 1.2
EX. (0.039 – 0.047) ———
IN. & EX. ——— (0.001)
(INTAKE) INNER ——— (1.38)
37.8
OUTER ——— (1.49)
(EXHAUST) ——— (1.60)
INNER (11.68 – 14.33 Ibs) ———
14.0 – 14.2 kgf
OUTER (30.86 – 31.31 Ibs) ———
(44.75 – 51.37 Ibs) ———
10-3 VL1500K1 (’01 - MODEL)

ITEM STANDARD LIMIT
Cam height 35.680 – 35.730 35.38
IN. (1.4047 – 1.4067) (1.393)
36.880 – 36.930 36.58
EX. (1.4521 – 1.4537) (1.440)
IN. & EX. (0.0013 – 0.0026) (0.0060)
Front & Rear (0.004)
Rocker arm I.D. 14.000 – 14.018 ———
IN. (0.5511 – 0.5519)
16.000 – 16.018 ———
EX. (0.6299 – 0.6303)
IN. (0.5498 – 0.5506)
15.966 – 15.984 ———
EX. (0.6286 – 0.6293)
(0.002)
(0.002)

ITEM STANDARD LIMIT
Campression pressure 1 000 – 1 400 kPa 800 kPa
(Automatic de-compression
actuated) (10 – 14 kgf/cm2
142 – 199 psi ) ( 8 kgf/cm2
144 psi )
———
( 2 kgf/cm2
28 psi )
(0.0008 – 0.0012) (0.0047)
(3.7795 – 3.7801) Scratches
Piston diam. 95.975 – 95.990
(3.7785 – 3.7791) 95.88
Measure at 16 mm (0.6 in) from the skirt end. (37.7748)
(0.002)
1st T Approx.
(0.53) (0.43)
14.0 11.2
2nd T Approx.
(0.55) (0.44)
VL1500K1 (’01 - MODEL) 10-4
ITEM STANDARD LIMIT

1st (0.012 – 0.018) (0.028)
0.45 – 0.60 1.00
2nd (0.018 – 0.024) (0.039)
1st (0.007)
——— 0.150
2nd (0.006)
1st (0.0476 – 0.0484)
1.510 – 1.530 ———
2nd (0.0594 – 0.0602)
2.810 – 2.830 ———
Oil (0.1106 – 0.1114)
1st (0.0457 – 0.0463)
1.470 – 1.490 ———
2nd (0.0579 – 0.0587)
Piston pin bore 23.002 – 23.008 23.030
(0.9056 – 0.9058) (0.9067)
Piston pin O.D. 22.992 – 23.000 22.980
(0.9052 – 0.9055) (0.9047)

ITEM STANDARD LIMIT
(0.9061 – 0.9064) (0.9071)
Conrod big end side clearance 0.10 – 0.200.3
(0.004 – 0.008) (0.012)
(0.864 – 0.866)
Crank pin width 22.10 – 22.15 ———
(0.870 – 0.872)
(0.0009 – 0.0017) (0.0031)
Crank pin O.D. 49.982 – 50.000 ———
(1.9678 – 1.9685)
(0.0008 – 0.0020) (0.0031)
(2.0459 – 2.0465)
(2.0472 – 2.0478)
thickness (0.0758 – 0.0856)
Crankshaft thrust clearance 0.05 – 0.10
———
(0.002 – 0.004)
Crankshaft runout 0.05
———
(0.002)
10-5 VL1500K1 (’01 - MODEL)
OIL PUMP
ITEM STANDARD LIMIT
at 3 000 r/min.

ITEM STANDARD LIMIT
(0.114 – 0.122) (0.102)
(0.614 – 0.622) (0.583)
Driven plate distortion 0.10
——— (0.004)
Clutch spring free length * 34.47 * 32.7
(1.357) (1.29)
Clutch master cylinder bore 14.000 – 14.043
(0.5512 – 0.5529) ———
Clutch master cylinder piston 13.957 – 13.984
diam. (0.5495 – 0.5506) ———
Clutch release cylinder bore 33.600 – 33.662
(1.3228 – 1.3253) ———
Clutch release cylinder piston 33.550 – 33.575
diam. (1.3209 – 1.3218) ———
TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Gear ratios Low 3.000 (36/12) ———
2nd 1.823 (31/17) ———
3rd 1.333 (28/21) ———
4th 1.041 (25/24) ———
Top 0.884 (23/26) ———
(0.004 – 0.012) (0.020)
Shift fork groove width 5.50 – 5.60
(0.217 – 0.220) ———
Shift fork thickness 5.30 – 5.40
(0.209 – 0.213) ———
Damper spring free length 73.6
——— (2.90)
Gearshift lever height 82
(3.23) ———
VL1500K1 (’01 - MODEL) 10-6
SHAFT DRIVE Unit: mm (in)

ITEM STANDARD LIMIT
(0.001 – 0.006) ———
(0.001 – 0.025) ———
CARBURETOR
STANDARD
ITEM
E-28 E-24 * E-02, 19
Carburetor type BDSR36 ← ←
Bore size 36.5 mm ← ←
I.D. No. 10F1 10F2 * 10F9
Idle r/min. 1 000 ± 100 r/min. ← ←
← ←
(0.28 ± 0.02 in)
Main jet (M.J.) F: # F: #112.5
←
R: # R: #110
Jet needle (J.N.) F: 5D95-56 F: 5D94-56-3 * F: 5D124-3
R: 5E9-56 R: 5E8-56-3 R: 5E19-3
Needle jet (N.J.) P-0 * P-0M
Throttle valve (Th.V.) #90 ← ←
Pilot jet (P.J.) # #32.5 ←
Pilot screw (P.S.) PRE-SET PRE-SET * PRE-SET
(
F: 2 1/4 turns back
R: 2 1/8 turns back ) ( ) (
F: 2 turns back
R: 2 turns back
F: 1 3/4 turns back
R: 1 3/8 turns back )
Throttle cable play 2.0 – 4.0 mm
(0.08 – 0.16 in) ← ←
CARBURETOR
STANDARD
ITEM
E-03 E-33 P-37
I.D. No. 10F1 10F7 10F6
Idle r/min. 1 000 ± 100 r/min. ← ←
(0.28 ± 0.02 in) ← ←
Main jet (M.J.) F: # F: #112.5
←
R: # R: #110
R: 5E9-56 ← R: 5E8-56-3
Needle jet (N.J.) ← P-0
Throttle valve (Th.V.) # 90 ← ←
Pilot jet (P.J.) # ← #32.5
PRE-SET ←
( F: 2 turns back
R: 2 turns back )
(0.08 – 0.16 in) ← ←
10-7 VL1500K1 (’01 - MODEL)

Ignition timing 2° B.T.D.C. at 1 000 r/min.
Firing order R.F
Type DENSO: X22EPR-U9
0.8 – 0.9
Gap (0.031 – 0.035)
Plug cap –
tap
Generator no-load voltage
(when engine is cold) More than 80 V (AC) at 5 000 r/min.
Voltage 12 V
Standard
1.320 at 20°C (68°F)
electrolyte S.G.
Fuse size HI 15 A
Headlight
LO 15 A
Signal 15 A
Ignition 10 A
Main 30 A
Power source 10 A
WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 28, 33 E-24 Others
LO 55 ← ←
Position light 4
Turn signal light 21/5 21 ←
Running light 5
VL1500K1 (’01 - MODEL) 10-8

ITEM STANDARD LIMIT
Rear brake pedal height 98
———
(3.86)
Brake disc thickness 5.8 – 6.2 5.5
Front (0.228 – 0.244) (0.22)
6.6 – 7.0 6.3
Rear (0.260 – 0.276) (0.25)
Brake disc runout 0.30
———
(0.012)
Master cylinder bore 12.700 – 12.743
Front ———
(0.5000 – 0.5017)
12.700 – 12.743
Rear ———
(0.5000 – 0.5017)
Master cylinder piston diam. 12.657 – 12.684
Front ———
(0.4983 – 0.4994)
12.657 – 12.684
Rear ———
(0.4983 – 0.4994)
Brake caliper cylinder bore 45.000 – 45.076
Front ———
(1.7717 – 1.7746)
42.850 – 42.926
Rear ———
(1.6870 – 1.6900)
Brake caliper piston diam. 44.930 – 44.980
Front (1.7689 – 1.7709) ———
42.770 – 42.820
Rear (1.6839 – 1.6858) ———
Wheel rim runout 2.0
Axial ——— (0.08)
2.0
Radial ——— (0.08)
Wheel axle runout 0.25
Front ——— (0.010)
0.25
Rear ——— (0.010)
Wheel rim size Front 16 × MT3.50 ———
Rear 15M/C × MT5.00 ———
Tire size Front 150/80-16 71H ———
Rear 180/70-15M/C 76H ———
Tire tread depth 1.6
Front ——— (0.06)
2.0
Rear ——— (0.08)
10-9 VL1500K1 (’01 - MODEL)

(5.5)
(23.03) (22.56)
(6.65)
set length (8.74)
(4.6)
TIRE PRESSURE
TIRE PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi
FRONT 200 2.00 29 200 2.00 29
REAR 250 2.50 36 250 2.50 36
FUEL + OIL
ITEM STANDARD LIMIT
thyl Tertiary Butyl Ether), less than 10% ethanol, E-03, 28, 33
Fuel tank 15.0 L
(4.0/3.3 US/Imp gal)
Change (3.9/3.3 US/lmp qt)
Filter 4 300 ml
5 000 ml
Overhaul (5.3/4.4 US/lmp qt)
(14.8/15.5 US/lmp oz)
Final
(6.8/7.0 – 7.4/7.7 US/lmp oz)
VL1500K1 (’01 - MODEL) 10-10
ENGINE INSTALLATION
50 N.m
23 N.m
5.0 kgf.m
( )
36.0 lb-ft ( 2.3 kgf.m
16.5 lb-ft )
50 N.m 79 N.m
5.0 kgf.m 7.9 kgf.m
( )
36.0 lb-ft ( 57.0 lb-ft )
50 N.m
5.0 kgf.m
( 36.0 lb-ft)
23 N.m
2.3 kgf.m
(16.5 lb-ft)
79 N.m
7.9 kgf.m
(57.0 lb-ft )
ADDITION
!
ITEM mm in
1 205 8.07
2 *265 *10.43
Bolt
3 160 6.30
4 140 5.51 The bolt 2 is changed and the washer is added.
10-11 VL1500K1 (’01 - MODEL)
PAIR (AIR SUPPLY) SYSTEM DIAGRAM

(EXCEPT P-37) To air cleaner box
PAIR control valve
PAIR control valve To cylinder head

(Vacuum hose)
Reed valve
No. 2 cylinder
No. 1 cylinder
FRESH AIR
EXHAUST GAS
To air cleaner To 3-way
box connector
PAIR cover PAIR air cleaner hose PAIR valve vacuum hose
(EXCEPT P-37)
PAIR control valve

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING
No. 1 cylinder head
No. 2 cylinder head
PAIR pipe
VL1500K1 (’01 - MODEL)
10-12
10-13 VL1500K1 (’01 - MODEL)
PAIR (AIR SUPPLY) SYSTEM INSPECTION

(EXCEPT P-37)
• Remove the PAIR cover. ("3-3)
HOSES AND PIPES

Inspect the hoses and pipes for wear or damage.
Inspact that the hoses and pipes are securely connected.
PAIR CONTROL VALVE
Inspect the PAIR control valve for damage of the body.
REED VALVE OF PAIR CONTROL VALVE
• Remove the PAIR control valve.
• Remove the reed valves.
Inspect the reed valve.
If the carbon deposit is found in the reed valve, replace the PAIR
control valve with a new one.
PAIR CONTROL VALVE

• Remove the PAIR control valve.
Blow the air inlet port of the control valve as shown in the illus-
tration. If air does not flow out, replace the control valve with a
new one.
Connect the vacuum pump to the vacuum port of the control

valve as shown in the illustration. Apply negative pressure slowly
to the control valve and blow the above manner. If air does not
become flow out within the specification, the control valve is
normal condition.
If the control valve does not function within the specification,
replace the control valve with a new one.
Negative pressure range: 30.7 – 40 kPa (230 – 300 mmHg)
# 09917-47010: Vacuum pump gauge
$
Use a hand operated vacuum pump to prevent the con-

trol valve damage.
VL1500K1 (’01 - MODEL) 10-14
WIRE HARNESS ROUTING
Clamp
Clamp
Fuel level gauge Wiring harness
Clamp Brake light/Taillight Ignitor
Fuel pump Starter relay
Wiring harness
Wiring harness
Clamp
Clamp Fuel catch tank
Clamp
Clamp
Wiring harness
Wiring harness
MAP
Automatic sensor
de-compression Automatic
relay de-compression
solenoid
Ignition coil
Horn (Except for

E-03, 24, 28, 33)
Fuel tank
Clamp
Horn
(Except for E-03,
Fuse box 24, 28, 33)
Turn signal/
side-stand relay Battery
Rear brake light switch Starter motor
Battery - Rear brake light switch
Oil pressure switch
Wiring harness
Clamp Rear brake light switch
Clamp Clamp
Rear brake light switch

Battery - Engine
Oil pressure switch
Clamp
10-15 VL1500K1 (’01 - MODEL)
This manual describes service data, service specifications and servicing procedures which
differ from those of the VL1500K1 (’01-MODEL).
CONTENTS
SPECIFICATIONS .............................................................................. 11-1
FRONT BRAKE .................................................................................. 11-3
CONSTRUCTION............................................................................ 11-3
BRAKE PAD REPLACEMENT ....................................................... 11-4
BRAKE FLUID REPLACEMENT .................................................... 11-4
BRAKE CALIPER REMOVAL AND DISASSEMBLY .................... 11-5
BRAKE CALIPER INSPECTION.................................................... 11-6
BRAKE DISC INSPECTION ........................................................... 11-6
BRAKE CALIPER REASSEMBLY AND REMOUNTING .............. 11-7
REAR BRAKE .................................................................................... 11-9
CONSTRUCTION............................................................................ 11-9
BRAKE PAD REPLACEMENT ....................................................... 11-10
BRAKE FLUID REPLACEMENT .................................................... 11-10
BRAKE CALIPER REMOVAL AND DISASSEMBLY .................... 11-11
CALIPER INSPECTION ................................................................. 11-12
CALIPER REASSEMBLY AND REMOUNTING ............................ 11-12
WIRE HARNESS ROUTING .............................................................. 11-14
FRONT BRAKE HOSE ROUTING ..................................................... 11-16
REAR BRAKE HOSE ROUTING ....................................................... 11-18
SERVICE DATA .................................................................................. 11-19
NOTE:
Any differences between the VL1500K1 (’01-model) and VL1500K2 (’02-model) in specifica-
tions and service data are indicated with an asterisk mark (*).
11
11-1 VL1500K2 (’02-MODEL)
SPECIFICATIONS
Overall length ............................................................... 2 525 mm (99.4 in)
Overall width ................................................................ 965 mm (38.0 in)
Overall height ............................................................... 1 165 mm (45.9 in)
Wheelbase ................................................................... 1 700 mm (66.9 in)
Ground clearance ........................................................ 145 mm ( 5.7 in)
Seat height ................................................................... 700 mm (27.6 in)
Dry mass ...................................................................... * 299 kg (659 lbs)
ENGINE
Type ............................................................................. 4-stroke, Air-cooled, OHC
Number of cylinders ..................................................... 2
Bore ............................................................................. 96 mm (3.780 in)
Stroke ........................................................................... 101 mm (3.976 in)
Displacement ............................................................... 1 462 cm3 (89.2 cu. in)
Compression ratio ........................................................ 8.5 : 1
Carburetor .................................................................... MIKUNI BDSR36, twin
Air cleaner .................................................................... Non-woven fabric element
Starter system .............................................................. Electric
Lubrication system ....................................................... Wet sump
Idle speed .................................................................... 1 000 ± 100 r/min
DRIVE TRAIN
Clutch ........................................................................... Wet multi-plate type
Transmission ................................................................ 5-speed constant mesh
Gearshift pattern .......................................................... 1-down, 4-up
Primary reduction ratio ................................................ 1.490 (76/51)
Final reduction ratio ..................................................... 2.666 (19/19 × 32/12)
Secondary reduction ratio ........................................... 0.852 (29/34)
Gear ratios, Low ........................................................... 3.000 (36/12)
2nd ........................................................... 1.823 (31/17)
3rd ............................................................ 1.333 (28/21)
4th ............................................................. 1.041 (25/24)
Top ............................................................ 0.884 (23/26)
Drive system ................................................................ Shaft drive
VL1500K2 (’02-MODEL) 11-2
CHASSIS
Front suspension ......................................................... Telescopic, coil spring, oil damped
Rear suspension .......................................................... Link type, coil spring, oil damped
Front suspension stroke .............................................. 140 mm (5.5 in)
Rear wheel travel ......................................................... 118 mm (4.6 in)
Caster .......................................................................... 32°
Trail .............................................................................. 138 mm (5.43 in)
Steering angle.............................................................. 39° (right & left)
Turning radius .............................................................. 3.1 m (10.2 ft)
Front brake ................................................................... * Disk brake, twin
Rear brake ................................................................... Disk brake
Front tire size ............................................................... 150/80-16 71H, tubeless
Rear tire size ................................................................ 180/70-15M/C 76H, tubeless
ELECTRICAL
Ignition type ................................................................. Electronic ignition (Transistorized)
Ignition timing ............................................................... 2° B.T.D.C. at 1 000 r/min
Spark plug .................................................................... NGK DPR7EA-9 or DENSO X22EPR-U9
Battery ......................................................................... 12V 50.4 kC (14Ah)/10 HR
Generator ..................................................................... Three-phase A.C. generator
Main fuse ..................................................................... 30A
Fuse ............................................................................. 15/15/15/10/10A
Headlight ...................................................................... 12V 60/55W (H4)
Position/Parking light ................................................... 12V 4W ..... Except E-03, 24, 28, 33
Brake light/Taillight ....................................................... 12V 21/5W
Turn signal light ............................................................ 12V 21/5W ..... E-03, 28, 33
12V 21W ..... Others
Speedometer light........................................................ 12V 0.84W × 2
Fuel level warning light ................................................ 12V 1.7W
Turn signal indicator light ............................................. 12V 1.7W
Neutral indicator light ................................................... 12V 1.7W
High beam indicator light ............................................. 12V 1.7W
Oil pressure indicator light ........................................... LED
CAPACITIES
Fuel tank ...................................................................... 15.0 L (4.0/3.3 US/Imp gal)
Engine oil, oil change .................................................. 3 700 ml (3.9/3.3 US/Imp qt)
with filter change ....................................... 4 300 ml (4.5/3.8 US/Imp qt)
overhaul ..................................................... 5 000 ml (5.3/4.4 US/Imp qt)
Final gear oil ................................................................ 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)
Front fork oil (each leg) ................................................ 439 ml (14.8/15.5 US/Imp oz)
11-3 VL1500K2 (’02-MODEL)
FRONT BRAKE
CONSTRUCTION
1 Dust boot
2 Piston set
3 Brake hose
4 Brake hose clamp
5 Dust seal
6 Piston seal
7 Piston
8 Brake caliper holder
9 Shim
0 Brake pad
A Spring
B Clip
C Pin
A Front master cylinder

mounting bolt
B Brake caliper mounting
bolt
C Brake caliper air bleeder
valve
D Brake hose union bolt
E Brake hose union bolt
#
ITEM N. m Kgf.m lb-ft
A 10 1.0 7.0
B 35 3.5 25.5
C 7.5 0.75 5.5
DE 23 2.3 16.5
!
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid
left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
"
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.
VL1500K2 (’02-MODEL) 11-4
BRAKE PAD REPLACEMENT

• Remove the bolt caps and brake caliper mounting bolts.
• Remove the brake pads and shims by removing the clip 1 and
pad mounting pin 2.
"
* Do not operate the brake lever while dismounting the
pads.
* Replace the brake pads as a set, otherwise braking per-
formance will be adversely affected.
• Install the new brake pads together with the shims.

# Pad mounting pin: 16 N.m (1.6 kgf.m, 11.6 lb-ft)
NOTE:
After replacing the brake pads, pump the brake lever few times to
check for proper brake operation and then check the brake fluid
level.
BRAKE FLUID REPLACEMENT

• Place the motorcycle on a level surface and keep the handle-
bars straight.
• Remove the brake fluid reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with new brake fluid.
• Connect a clear hose to the caliper air bleeder valve and insert
the other end of hose into a receptacle.
• Loosen the air bleeder valve and pump the brake lever until old
brake fluid flows out of the bleeder system.
• Close the caliper air bleeder valve and disconnect a clear hose.
Fill the reservoir with new fluid to the upper mark of the reser-
voir.
$ Specification and Classification: DOT 4
"
Bleed air from the brake system.
# Air bleeder valve: 7.5 N.m (0.75 kgf.m, 5.5 lb-ft)

11-5 VL1500K2 (’02-MODEL)
BRAKE CALIPER REMOVAL AND DISASSEM-

BLY
• Remove the brake hose by removing the union bolt 1 and catch
the brake fluid in a suitable receptacle.
NOTE:
Place a rag underneath the union bolt on the brake caliper to catch
any spilt brake fluid.
• Remove the brake caliper by removing the caliper mounting bolts.
"
Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods of time.
!
Brake fluid, if it leaks, will interfere with safe running and
discolor painted surfaces. Check the brake hose and hose
joints for cracks and fluid leakage.
• Remove the brake pads. (% 11-5)

• Remove the spring 2.
• Place a rag over the pistons to prevent it from popping out and
then force out the pistons using compressed air.
"
Do not use high pressure air to prevent piston damage.
• Remove the dust seals and piston seals.

"
Do not reuse the dust seals and piston seals to prevent
fluid leakage.
VL1500K2 (’02-MODEL) 11-6
• Remove the brake caliper holder 1.
BRAKE CALIPER INSPECTION

BRAKE CALIPER
Inspect each brake caliper cylinder wall for nicks, scratches or
other damage
BRAKE CALIPER PISTONS
Inspect the brake caliper piston surface for any scratches or other
damage.
RUBBER PARTS
The removed rubber barts 1 should be replaced with new ones.
BRAKE DISC INSPECTION

Visually check the brake disc for damage or cracks.
Measure the thickness with a micrometer.
Replace the disc if the thickness is less than the service limit or if
damage is found.
& Brake disc thickness
(Front): Service Limit: 4.5 mm (0.18 in)
(Rear) : Service Limit: 6.3 mm (0.25 in)
' 09900-20205: Micrometer (0 – 25 mm)
Measure the runout with a dial gauge.

Replace the disc if the runout exceeds the service limit.
& Brake disc runout: Service Limit: 0.30 mm (0.012 in)
' 09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
11-7 VL1500K2 (’02-MODEL)
BRAKE CALIPER REASSEMBLY AND RE-

MOUNTING
Reassemble and remount the brake caliper in the reverse order of
removal and disassembly. Pay attention to the following points:
• Wash the caliper bores and pistons with the specified brake fluid.
Thoroghly wash the dust seal grooves and piston seal grooves.
"
* Wash the brake caplier components with new brake fluid
before reassembly.
* Do not wipe the breke fluid off after washing the com-
ponents.
* When washing the components, use the specified brake
fluid. Never usedifferent types of fluid or cleaning sol-
vent such as gasoline, kerosine, etc.
* Replace the piston seals and dust seals with new ones.
* Apply brake fluid to all of the seals, brake caliper bores
and pistons before reassembly.
• Apply SUZUKI SILICON GREASE to the brake caliper holder.

( 09900-25100: SUZUKI SILICONE GREASE
• When installing the spring 1, pay attention to the direction of it.

VL1500K2 (’02-MODEL) 11-8
• Tighten the brake caliper mounting bolts 1 and brake hose union
Clamp Clamp
Clamp Ignitor
Brake light/Taillight
bolt 2 to the specified torque.

# Brake caliper mounting bolt 1: 35 N.m Wiring harness
Wiring harness
Clamp
(3.5 kgf.m, 25.5 lb-ft)

Clamp
Fuel catch tank
Clamp
Clamp
Wiring harness
Wiring harness
Brake hose union bolt 2: 23 N m (2.3 kgf.m, 16.5 lb-ft)

. MAP
Automatic sensor
solenoid
Ignition coil
NOTE: Fuel tank

Horn (Except for
E-03, 24, 28, 33)
Clamp
Horn
Before remounting the caliper, push the piston all the way into the Fuse box
Turn signal/side-stand relay
Rear brake light switch
(Except for E-03,
24, 28, 33)
Battery
Battery - Starter motor
caliper.
Oil pressure switch Rear brake light switch
Wiring harness
Clamp
Rear brake light switch Clamp
Battery-
Oil pressure switch
"
Clamp Engine
Bleed air from the system after installing the brake cali-
per.
11-9 VL1500K2 (’02-MODEL)
REAR BRAKE
CONSTRUCTION
1 Brake pad mounting pin
2 O-ring
3 Piston seal
4 Dust seal
5 Piston
6 Brake pad cover
7 Shim
8 Damper shim
9 Brake pad
0 Diaphragm
A Reservoir tank
B Connector
C O-ring
D Dust boot
E Snap ring
F Push rod
G Piston
H Secondary cup
I Return spring
#
ITEM N. m Kgf.m lb-ft
A 7.5 0.75 5.5
B 21 2.1 15.1
C 35 3.5 25.5
D, F 23 2.3 16.5
E 18 1.8 13.0
A Brake caliper air bleeder valve

B Brake caliper housing bolt
C Brake caliper mounting bolt
D Brake hose union bolt
E Brake master cylinder rod lock nut
F Brake hose union bolt
!
* This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix
different types of fluid such as silicone-based or petroleum-based.
* Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid
left over from the last servicing or stored for long periods.
* When storing the brake fluid, seal the container completely and keep away from children.
* When replenishing brake fluid, take care not to get dust into fluid.
* When washing brake components, use fresh brake fluid. Never use cleaning solvent.
* A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
"
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc.
VL1500K2 (’02-MODEL) 11-10
BRAKE PAD REPLACEMENT

• Remove the brake pad cover 1.
• Remove the brake pad mounting pin 2.
• Remove the prake pads, damper shims and shims.
"
* Do not operate the brake pedal while dismounting the
pads.
* Replace the brake pads as a set, otherwise braking per-
formance will be adversely affected.
• Install the new brake pads along with the damper shims 3 and
shims 4.
• Tighten the brake pad mounting pin 5.

# Brake pad mounting pin: 16 N.m (1.6 kgf.m, 11.5 lb-ft)
NOTE:
After replacing the brake pads, pump the brake pedal few times to
operate the brake correctly and then check the brake fluid level.
BRAKE FLUID REPLACEMENT

• Remove the brake fluid reservoir cap.
• Replace the brake fluid in the same manner as the front brake.
(% 11-5)
"
Bleed air from the brake system.
11-11 VL1500K2 (’02-MODEL)
BRAKE CALIPER REMOVAL AND DISASSEM-

BLY
• Remove the 1st muffler 1.
• Remove the union bolt 2 and catch the brake fluid in a suitable
receptacle.
"
Never reuse the brake fluid left over from previous ser-
vicing and stored for long periods.
!
Brake fluid, if it leaks, will interfere with safe running and
discolor painted surfaces. Check the brake hose and hose
joints for cracks and fluid leakage.
• Loosen the rear axle nut.

• Remove the caliper mounting bracket bolt 3 and nut.
• Remove the brake caliper by removing the mounting bolts 4.

NOTE:
Slightly loosen the caliper housing bolts 5 before removing the
caliper mounting bolts to facilitate later disassembly.
• Remove the brake pads. (% 11-11)

• Remove the caliper housing bolts 5.
• Separate the caliper halves.
VL1500K2 (’02-MODEL) 11-12
• Place a rag over the pistons to prevent them from popping out
and then force out the pistons using compressed air.
"
Do not use high pressure air to prevent piston damage.
• Remove the dust seals and piston seals.
"
Do not reuse the dust seals and piston seals to prevent
brake fluid leakage.
CALIPER INSPECTION
BRAKE CALIPER INSPECTION: % 11-7
PISTON: % 11-7
DISC: % 11-7
CALIPER REASSEMBLY AND REMOUNTING

Reassemble and remount the caliper in the reverse order of re-
moval and disassembly. Pay attention to the following points:
"
* Wash the caliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or gaso-
line to wash them.
* Apply brake fluid to the caliper bore and piston to be
inserted into the bore.

• Install the O-ring 1.
"
Replace the O-ring with a new one.
11-13 VL1500K2 (’02-MODEL)
• Tighten each bolt and nut to the specified torque.

# Brake caliper mounting bolt 1: 35 N.m
(3.5 kgf.m, 25.5 lb-ft)
NOTE:
Before remounting the caliper, push the piston all the way into the
caliper.
# Rear axle nut 2: 110 N.m (11.0 kgf.m, 79.5 lb-ft)

Brake caliper mounting bracket bolt/nut 3
: 60 N.m (6.0 kgf.m, 43.5 lb-ft)
Brake caplier housing bolt 4: 21 N.m (2.1 kgf.m, 15.1 lb-ft)
# Brake hose union bolt 5: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
• When installing the 1st muffler, apply gas sealer to the inside
and outside of the exhaust pipe connector.
EXHAUST GAS SEALER: PERMATEX 1372
# Muffler connecting bolt: 23 N.m (2.3 kgf.m, 16.5 lb-ft)
Muffler mounting bolt : 23 N.m (2.3 kgf.m, 16.5 lb-ft)
"
Bleed air from the system after reassembling the caliper.
Clamp Clamp
Clamp Ignitor
Brake light/Taillight
Wiring harness
Wiring harness
Clamp
Clamp
WIRE HARNESS ROUTING
Fuel catch tank

Clamp
Clamp
Wiring harness
Wiring harness
MAP
Automatic sensor
solenoid
Ignition coil
Horn (Except for

E-03, 24, 28, 33)
Fuel tank
Clamp
Horn
(Except for E-03,
Fuse box 24, 28, 33)
Turn signal/side-stand relay
Battery
Rear brake light switch Starter motor
Battery -
Oil pressure switch Rear brake light switch
Wiring harness
Clamp
Rear brake light switch Clamp
Battery-
Oil pressure switch
Clamp Engine
11-14
11-15
Headlight housing Wiring harness

Clamp
Wiring harness Handlebar switch (R, L)
Wiring harness
Clamp Starter motor
Clamp
Battery +
Headlight
Horn (Except E-03, 24, 28, 33) Clamp
Horn Clamp
Speedometer Wiring harness
Starter relay
Fuel pump
Horn (Except E-03, 24, 28, 33) Ignitor
Ignitor
(For E-03, 24, 28, 33)
Ignition switch
Horn Fuel tank
Ignition coil Fuel pump The indent of the cushion
(Except E-03, 24, 28, 33)
Clamp must not face ignitor side.
Wiring harness
Starter motor Clutch pipe
Battery + Battery
Clamp
Battery + To regulator/rectifier
Wiring harness
Clamp
Starter motor Clamp
Side-stand switch Regulator/rectifier

Clamp Neutral indicator light switch
Generator
Neutral indicator light switch Side-stand switch
Generator
Side-stand switch Clamp
Clamp
VL1500K2 (’02-MODEL) 11-16
FRONT BRAKE HOSE ROUTING
90
˚
14
˚
˚
42
Clamp
After touching the brake hose clamp

stopper to the lower bracket, tighten
the bolt. (L & R)
After touching the brake hose union

to the stopper, tighten the union bolt
to the specified torque.
11-17 VL1500K2 (’02-MODEL)
Clamp
Clamp
Clamp
Brake hose Brake hose
After touching the brake hose clamp stopper to the

lower bracket, tighten the bolt.
21˚
90˚
Brake hose must be passed over the

brake support boss and caliper bracket.
After touching the brake hose union to the

REAR BRAKE HOSE ROUTING
stopper, tighten the union bolt to the

specified torque.
Clamp Clamp
Clamp
After touching the clamp stopper to the

frame, tighten the bolt.
11-18
11-19 VL1500K2 (’02-MODEL)
SERVICE DATA
ITEM STANDARD LIMIT
Valve diam. 33
IN. (1.3) ———
40
EX. (1.6) ———
Lash-adjuster plunger stroke 0 – 0.5
(0 – 0.02) ———
Valve guide to valve stem 0.010 – 0.037
clearance IN. (0.0004 – 0.0015) ———
0.040 – 0.070
EX. (0.0016 – 0.0028) ———
IN. & EX. ———
(0.014)
Valve guide I.D. 5.500 – 5.512
IN. (0.2165 – 0.2170) ———
7.000 – 7.015
EX. (0.2756 – 0.2762) ———
Valve stem O.D. 5.475 – 5.490
IN. (0.2156 – 0.2161) ———
6.945 – 6.960
EX. (0.2734 – 0.2740) ———
IN. & EX. ——— (0.002)
IN. & EX. ——— (0.02)
IN. ——— (0.10)
2.2
EX. ——— (0.09)
Valve seat width 0.9 – 1.1
IN. (0.035 – 0.043) ———
1.0 – 1.2
EX. (0.039 – 0.047) ———
IN. & EX. ——— (0.001)
(INTAKE) INNER ——— (1.38)
37.8
OUTER ——— (1.49)
(EXHAUST) ——— (1.60)
INNER (11.68 – 14.33 Ibs) ———
14.0 – 14.2 kgf
OUTER (30.86 – 31.31 Ibs) ———
(44.75 – 51.37 Ibs) ———
VL1500K2 (’02-MODEL) 11-20

ITEM STANDARD LIMIT
Cam height 35.680 – 35.730 35.38
IN. (1.4047 – 1.4067) (1.393)
36.880 – 36.930 36.58
EX. (1.4521 – 1.4537) (1.440)
IN. & EX. (0.0013 – 0.0026) (0.0060)
Front & Rear (0.004)
Rocker arm I.D. 14.000 – 14.018 ———
IN. (0.5511 – 0.5519)
16.000 – 16.018 ———
EX. (0.6299 – 0.6303)
IN. (0.5498 – 0.5506)
15.966 – 15.984 ———
EX. (0.6286 – 0.6293)
(0.002)
(0.002)

ITEM STANDARD LIMIT
Campression pressure 1 000 – 1 400 kPa
(Automatic de-compression
actuated) (10 – 14 kgf/cm2
142 – 199 psi ) ———

———
( 2 kgf/cm2
28 psi )
(0.0008 – 0.0012) (0.0047)
(3.7795 – 3.7801) Scratches
Piston diam. 95.975 – 95.990
(3.7785 – 3.7791) 95.88
Measure at 16 mm (0.6 in) from the skirt end. (37.7748)
(0.002)
1st T Approx.
(0.53) (0.43)
14.0 11.2
2nd T Approx.
(0.55) (0.44)
11-21 VL1500K2 (’02-MODEL)
ITEM STANDARD LIMIT

1st (0.012 – 0.018) (0.028)
0.45 – 0.60 1.00
2nd (0.018 – 0.024) (0.039)
1st (0.007)
——— 0.150
2nd (0.006)
1st (0.0476 – 0.0484)
1.510 – 1.530 ———
2nd (0.0594 – 0.0602)
2.810 – 2.830 ———
Oil (0.1106 – 0.1114)
1st (0.0457 – 0.0463)
1.470 – 1.490 ———
2nd (0.0579 – 0.0587)
Piston pin bore 23.002 – 23.008 23.030
(0.9056 – 0.9058) (0.9067)
Piston pin O.D. 22.992 – 23.000 22.980
(0.9052 – 0.9055) (0.9047)

ITEM STANDARD LIMIT
(0.9061 – 0.9064) (0.9071)
Conrod big end side clearance 0.10 – 0.20 0.3
(0.004 – 0.008) (0.012)
(0.864 – 0.866)
Crank pin width 22.10 – 22.15 ———
(0.870 – 0.872)
(0.0009 – 0.0017) (0.0031)
Crank pin O.D. 49.982 – 50.000 ———
(1.9678 – 1.9685)
(0.0008 – 0.0020) (0.0031)
(2.0459 – 2.0465)
(2.0472 – 2.0478)
thickness (0.0758 – 0.0856)
Crankshaft thrust clearance 0.05 – 0.10
———
(0.002 – 0.004)
Crankshaft runout 0.05
———
(0.002)
VL1500K2 (’02-MODEL) 11-22
OIL PUMP
ITEM STANDARD LIMIT
at 3 000 r/min.

ITEM STANDARD LIMIT
(0.114 – 0.122) (0.102)
(0.614 – 0.622) (0.583)
Driven plate distortion 0.10
——— (0.004)
Clutch spring free length 34.47 32.7
(1.357) (1.29)
Clutch master cylinder bore 14.000 – 14.043
(0.5512 – 0.5529) ———
Clutch master cylinder piston 13.957 – 13.984
diam. (0.5495 – 0.5506) ———
Clutch release cylinder bore 33.600 – 33.662
(1.3228 – 1.3253) ———
Clutch release cylinder piston 33.550 – 33.575
diam. (1.3209 – 1.3218) ———
DRIVE TRAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Gear ratios Low 3.000 (36/12) ———
2nd 1.823 (31/17) ———
3rd 1.333 (28/21) ———
4th 1.041 (25/24) ———
Top 0.884 (23/26) ———
(0.004 – 0.012) (0.020)
Shift fork groove width 5.50 – 5.60
(0.217 – 0.220) ———
Shift fork thickness 5.30 – 5.40
(0.209 – 0.213) ———
Damper spring free length 73.6
——— (2.90)
Gearshift lever height 82
(3.23) ———
(0.001 – 0.006) ———
(0.001 – 0.025) ———
11-23 VL1500K2 (’02-MODEL)
CARBURETOR
STANDARD
ITEM
E-28 E-24 E-02, 19
I.D. No. 10F1 10F2 10F9
Idle r/min. 1 000 ± 100 r/min. ← ←
← ←
(0.28 ± 0.02 in)
Main jet (M.J.) F: # F: #112.5
←
R: # R: #110
Jet needle (J.N.) F: 5D95-56 F: 5D94-56-3 F: 5D124-3
R: 5E9-56 R: 5E8-56-3 R: 5E19-3
Needle jet (N.J.) P-0 P-0M
Throttle valve (Th.V.) #90 ← ←
Pilot jet (P.J.) # #32.5 ←
Pilot screw (P.S.) PRE-SET PRE-SET PRE-SET
(
F: 2 1/4 turns back
R: 2 1/8 turns back ) (
F: 2 turns back
R: 2 turns back) (F: 1 3/4 turns back
R: 1 3/8 turns back )
(0.08 – 0.16 in) ← ←
CARBURETOR
STANDARD
ITEM
E-03 E-33 P-37
I.D. No. 10F1 10F7 10F6
Idle r/min. 1 000 ± 100 r/min. ← ←
(0.28 ± 0.02 in) ← ←
Main jet (M.J.) F: # F: #112.5
←
R: # R: #110
R: 5E9-56 ← R: 5E8-56-3
Needle jet (N.J.) ← P-0
Throttle valve (Th.V.) # 90 ← ←
Pilot jet (P.J.) # ← #32.5
PRE-SET ←
( F: 2 turns back
R: 2 turns back )
(0.08 – 0.16 in) ← ←
VL1500K2 (’02-MODEL) 11-24

Firing order R.F
Type DENSO: X22EPR-U9
0.8 – 0.9
Gap (0.031 – 0.035)
Plug cap –
tap
Generator no-load voltage
(when engine is cold) More than 80 V (AC) at 5 000 r/min.
Voltage 12 V
Standard
1.320 at 20°C (68°F)
electrolyte S.G.
Fuse size HI 15 A
Headlight
LO 15 A
Signal 15 A
Ignition 10 A
Main 30 A
Power source 10 A
WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 28, 33 E-24 Others
LO 55 ← ←
Position light 4
Turn signal light 21/5 21 ←
Running light 5
11-25 VL1500K2 (’02-MODEL)

ITEM STANDARD LIMIT
Rear brake pedal height 98
———
(3.86)
Brake disc thickness * 4.8 – 5.2 * 4.5
Front (0.189 – 0.205) (0.18)
6.6 – 7.0 6.3
Rear (0.260 – 0.276) (0.25)
Brake disc runout 0.30
———
(0.012)
Master cylinder bore * 15.870 – 15.913
Front ———
(0.6248 – 0.6265)
12.700 – 12.743
Rear ———
(0.5000 – 0.5017)
Master cylinder piston diam. * 15.827 – 15.854
Front ———
(0.6231 – 0.6242)
12.657 – 12.684
Rear ———
(0.4983 – 0.4994)
Brake caliper cylinder bore * 30.230 – 30.306
Front ———
(1.1902 – 1.1931)
* 30.230 – 30.306
Rear ———
(1.1902 – 1.1931)
Brake caliper piston diam. * 30.150 – 30.200
Front (1.1870 – 1.1890) ———
* 30.150 – 30.200
Rear (1.1870 – 1.1890) ———
Wheel rim runout 2.0
Axial ——— (0.08)
2.0
Radial ——— (0.08)
Wheel axle runout 0.25
Front ——— (0.010)
0.25
Rear ——— (0.010)
Wheel rim size Front 16 × MT3.50, 16M/C × MT3.50 ———
Rear 15M/C × MT5.00 ———
Tire size Front 150/80-16 71H, 150/80-16M/C 71H ———
Rear 180/70-15M/C 76H ———
Tire tread depth 1.6
Front ——— (0.06)
2.0
Rear ——— (0.08)
VL1500K2 (’02-MODEL) 11-26

(5.5)
(23.03) (22.56)
(6.65)
set length (8.74)
(4.6)
TIRE PRESSURE
TIRE PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi
FRONT 200 2.00 29 200 2.00 29
REAR 250 2.50 36 250 2.50 36
FUEL + OIL
ITEM STANDARD LIMIT
thyl Tertiary Butyl Ether), less than 10% ethanol, E-03, 28, 33
Fuel tank 15.0 L
(4.0/3.3 US/Imp gal)
Change (3.9/3.3 US/lmp qt)
Filter 4 300 ml
5 000 ml
Overhaul (5.3/4.4 US/lmp qt)
(14.8/15.5 US/lmp oz)
Final
(6.8/7.0 – 7.4/7.7 US/lmp oz)
Prepared by
4th Ed. February, 2002

1st Ed. December, 1997
Part No. 99500-39164-01E
Printed in Japan
452
Printed in Japan TK
W X Y K1 K2

Suzuki VL1500 '98-'02 Service Manual (99500-39164-01E)

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Suzuki VL1500 '98-'02 Service Manual (99500-39164-01E)

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VL1500

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT

CONROD + CRANKSHAFT Unit: mm (in)

CLUTCH Unit: mm (in)

TRANSMISSION Unit: mm (in) Except ratio

SHAFT DRIVE Unit: mm (in)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT

SUSPENSION Unit: mm (in)

Fuel tank 15.5 L (4.1/3.4 US/Imp gal) X-MODEL

FRONT BRAKE CALIPER Left

REAR BRAKE CALIPER

FUEL LEVEL GAUGE

Float position Resistance

Less than More than

SPEEDOMETER LIGHTING AUTOMATIC

B/Br . . . . . Black with Brown tracer

REAR BRAKE FUEL

B/Br . . . . . Black with Brown tracer

Y/W . . . . . Yellow with White tracer

B/Br . . . . . Black with Brown tracer

B/Y . . . . . Black with Yellow tracer

FRONT BRAKE HOSE ROUTING

Clamp the brake hose to the

Turn signal light

After touching the brake hose clamp

Clamp the brake

Brake hose must be passed

Brake caliper Reservoir tank

Brake hose Master cylinder

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT

CONROD + CRANKSHAFT Unit: mm (in)

CLUTCH Unit: mm (in)

TRANSMISSION Unit: mm (in) Except ratio

SHAFT DRIVE Unit: mm (in)

ELECTRICAL Unit: mm (in)

BRAKE + WHEEL Unit: mm (in)

SUSPENSION Unit: mm (in)

PAIR (AIR SUPPLY) SYSTEM DIAGRAM

PAIR control valve

PAIR control valve To cylinder head

PAIR control valve

No. 1 cylinder head

No. 2 cylinder head

PAIR (AIR SUPPLY) SYSTEM INSPECTION

HOSES AND PIPES

PAIR CONTROL VALVE

Connect the vacuum pump to the vacuum port of the control

Use a hand operated vacuum pump to prevent the con-

WIRE HARNESS ROUTING

Horn (Except for

Rear brake light switch

A Front master cylinder

BRAKE PAD REPLACEMENT

• Install the new brake pads together with the shims.

BRAKE FLUID REPLACEMENT