Manual Propietario Intruder - vl1500b

p
1st cover
VL1500B/T/BT
OWNER’S MANUAL
m 4/1 Cyan
Magenta
Yellow
Downloaded from www.Manualslib.com manuals search engine
Black
T
2nd cover
This manual should be considered a permanent part of the

motorcycle and should remain with the motorcycle when resold
or otherwise transferred to a new owner or operator. The
manual contains important safety information and instructions
which should be read carefully before operating the motorcycle.
VL1500B/T/BT (99011-06J52-01A) 8

IMPORTANT Please refer to the BREAK-IN (RUNNING-
IN) section for specific break-in recommen-
dations.
BREAK-IN (RUNNING-IN)
INFORMATION FOR YOUR MOTORCYCLE
The first 1600 km (1000 miles) are the most
important in the life of your motorcycle.
Proper break-in operation during this time
will help ensure maximum life and perfor-
mance from your new motorcycle. Suzuki
parts are manufactured of high quality mate-
rials and machined parts are finished to
close tolerances. Proper break-in operation
allows the machined surfaces to polish each
other and mate smoothly.
Motorcycle reliability and performance

depend on special care and restraint exer-
cised during the break-in period. It is espe-
cially important that you avoid operating the
engine in a manner which could expose the
engine parts to excessive heat.

 WARNING/ CAUTION/NOTICE/NOTE
Please read this manual and follow its NOTICE
instructions carefully. To emphasize special
information, the symbol  and the words Indicates a potential hazard that could
WARNING, CAUTION, NOTICE and NOTE result in vehicle or equipment damage.
have special meanings. Pay particular atten-
tion to messages highlighted by these signal NOTE: Indicates special information to
words: make maintenance easier or instructions
clearer.
 WARNING
Indicates a potential hazard that could
result in death or serious injury.
 CAUTION
Indicates a potential hazard that could
result in minor or moderate injury.

FOREWORD All information, illustrations and specifica-
tions contained in this manual are based on
Motorcycling is one of the most exhilarating the latest product information available at
sports and to ensure your riding enjoyment, the time of publication. Due to improve-
you should become thoroughly familiar with ments or other changes, there may be some
the information presented in this Owner’s discrepancies between information in this
Manual before riding the motorcycle. manual and your motorcycle. Suzuki
reserves the right to make changes at any
The proper care and maintenance that your time.
motorcycle requires is outlined in this man-
ual. By following these instructions explicitly Please note that this manual applies to all
you will ensure a long trouble-free operating specifications for all respective destinations
life for your motorcycle. Your authorized and explains all equipment. Therefore, your
Suzuki dealer has experienced technicians model may have different standard features
that are trained to provide your machine with from those shown in this manual.
the best possible service with the right tools
and equipment.

TABLE OF CONTENTS
CONSUMER INFORMATION 1
CONTROLS 2
FUEL, OIL AND COOLANT RECOMMENDATIONS 3
BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING 4
RIDING TIPS 5
INSPECTION AND MAINTENANCE 6
TROUBLESHOOTING 7
STORAGE PROCEDURE AND MOTORCYCLE CLEANING 8
SPECIFICATIONS
INDEX

CONSUMER INFORMATION
1
ACCESSORY USE AND MOTORCYCLE LOADING ................................................................................ 1-2
SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ....................................................... 1-6
LABELS ...................................................................................................................................................... 1-8
SERIAL NUMBER LOCATION ................................................................................................................... 1-8
NOISE CONTROL SYSTEM (AUSTRALIA ONLY) .................................................................................. 1-10
1-1

CONSUMER INFORMATION
 WARNING
ACCESSORY USE AND MOTORCYCLE Improper installation of accessories or
LOADING modification of the motorcycle may
cause changes in handling which could
ACCESSORY USE lead to an accident.
The addition of unsuitable accessories can
lead to unsafe operating conditions. It is not Never use improper accessories, and
possible for Suzuki to test each accessory make sure that any accessories that are
on the market or combinations of all the used are properly installed. All parts and
available accessories; however, your dealer accessories added to the motorcycle
can assist you in selecting quality accesso- should be genuine Suzuki parts or their
ries and installing them correctly. Use equivalent designed for use on this
extreme caution when selecting and install- motorcycle. Install and use them accord-
ing the accessories on your motorcycle and ing to their instructions. If you have any
consult your Suzuki dealer if you have any questions, contact your Suzuki dealer.
questions.
1-2

ACCESSORY INSTALLATION • Certain accessories displace the rider
GUIDELINES from his or her normal riding position.
• Install aerodynamic-affecting accesso- This limits the freedom of movement of
ries, such as a fairing, windshield, back- the rider and may limit his or her control
rests, saddlebags, and travel trunks, as ability.
low as possible, as close to the motorcy- • Additional electrical accessories may
cle and as near to the center of gravity overload the existing electrical system.
as is feasible. Check that the mounting Severe overloads may damage the wir-
brackets and other attachment hardware ing harness or create a dangerous situa-
are rigidly mounted. tion due to the loss of electrical power
• Inspect for proper ground clearance and during the operation of the motorcycle.
bank angle. Inspect that the accessory • Do not pull a trailer or sidecar. This
does not interfere with the operation of motorcycle is not designed to pull a
the suspension, steering or other control trailer or sidecar.
operations.
• Accessories fitted to the handlebars or
the front fork area can create serious
stability problems. This extra weight will
cause the motorcycle to be less respon-
sive to your steering control. The weight
may also cause oscillations in the front
end and lead to instability problems.
Accessories added to the handlebars or
front fork of the machine should be as
light as possible and kept to a minimum.
1-3

LOADING LIMIT • Never exceed the G.V.W. (Gross Vehicle
Weight) of this motorcycle. The G.V.W. is
 WARNING the combined weight of the machine,
accessories, payload, rider and passen-
Overloading or improper loading can ger. When selecting your accessories,
cause loss of motorcycle control and an keep in mind the weight of the rider as
accident. well as the weight of the accessories.
The additional weight of the accessories
Follow loading limits and loading guide- may not only create an unsafe riding
lines in this manual. condition but may also affect the riding
stability.
G.V.W.: 560 kg (1230 lbs)

at the tire pressure (cold)
Front: 225 kPa (2.25 kgf/cm2, 33 psi)
Rear: 280 kPa (2.80 kgf/cm2, 41 psi)
1-4

LOADING GUIDELINES • Improperly loading your motorcycle can
This motorcycle is primarily intended to reduce your ability to balance and steer
carry small items when you are not riding the motorcycle. You should ride at
with a passenger. Follow the loading guide- reduced speeds, less than 130 km/h (80
lines below: mph), when you are carrying cargo or
• Balance the load between the left and have added accessories.
right side of the motorcycle and fasten it • Adjust suspension setting as necessary.
securely.
• Keep cargo weight low and close to the
center of the motorcycle as possible.  WARNING
• Do not attach large or heavy items to the Placing objects in the space behind the
handlebars, front forks or rear fender. windshield can interfere with steering
• Do not install a luggage carrier or a lug- and can cause loss of control.
gage box protruding over the tail end of
the motorcycle. Do not carry any objects in the space
• Do not carry any items that protrude over behind the windshield.
the tail end of the motorcycle.
• Check that both tires are properly
inflated to the specified tire pressure for MODIFICATION
your loading conditions. Refer to page 6- Modification of the motorcycle, or removal of
59. original equipment may render the vehicle
unsafe or illegal.
1-5

SAFE RIDING RECOMMENDATION FOR RIDING APPAREL
MOTORCYCLE RIDERS Loose, fancy clothing can be uncomfortable
Motorcycle riding is great fun and an excit- and unsafe when riding your motorcycle.
ing sport. Motorcycle riding also requires Choose good quality motorcycle riding
that some extra precautions be taken to apparel when riding your motorcycle.
ensure the safety of the rider and passen-
ger. These precautions are: INSPECTION BEFORE RIDING
Review thoroughly the instructions in the
WEAR A HELMET INSPECTION BEFORE RIDING section of
Motorcycle safety equipment starts with a this manual. Do not forget to perform an
quality helmet. One of the most serious inju- entire safety inspection to ensure the safety
ries that can happen is a head injury. of the rider and its passenger.
ALWAYS wear a properly approved helmet.
You should also wear suitable eye protec- FAMILIARIZE YOURSELF WITH THE
tion. MOTORCYCLE
Your riding skill and your mechanical knowl-
edge form the foundation for safe riding
practices. We suggest that you practice
riding your motorcycle in a non-traffic situa-
tion until you are thoroughly familiar with
your machine and its controls. Remember
practice makes perfect.
1-6

KNOW YOUR LIMITS RIDE DEFENSIVELY
Ride within the boundaries of your own skill The most common type of motorcycle acci-
at all times. Knowing these limits and stay- dent occurs when a car traveling towards a
ing within them will help you to avoid acci- motorcycle turns round corner in front of the
dents. motorcyclist. Ride defensively. Wise motor-
cyclist uses a strategy of assuming they are
BE EXTRA SAFETY CONSCIOUS ON invisible to other drivers, even in broad day-
BAD WEATHER DAYS light. Wear bright, reflecting clothing. Turn
Riding on bad weather days, especially wet on the headlight and taillight every time even
ones requires extra caution. Braking dis- on a bright, sunny day to attract driver’s
tances double on a rainy day. Stay off of the attention. Do not ride in another driver’s
painted surface marks, manhole covers and blind spot.
greasy appearing areas as they can be
especially slippery. Use extreme caution at
railway crossings and on metal gratings and
bridges. When-ever in doubt about road
condition, slow down!
1-7

LABELS SERIAL NUMBER LOCATION
Read and follow all the labels on the motor- The frame and/or engine serial numbers are
cycle. Make sure you understand all of the used to register the motorcycle. They are
labels. Do not remove any labels from the also used to assist your authorized Suzuki
motorcycle. dealer when ordering parts or referring to
special service information.
1-8

The frame number 1 is stamped on the
steering head. The engine serial number 2
is stamped on the crankcase assembly.
Please write down the numbers in the box

provided below for your future reference.
Frame number:
Engine number:
1-9

NOISE CONTROL SYSTEM
(AUSTRALIA ONLY)
TAMPERING WITH NOISE CONTROL
SYSTEM PROHIBITED
Owners are warned that the law may pro-
hibit:
(a) The removal or rendering inoperative by
any person other than for purposes of
maintenance, repair or replacement, of
any device or element of design incorpo-
rated into any new vehicle for the pur-
pose of noise control prior its sale or
delivery to the ultimate purchaser or
while it is in use; and
(b) The use of the vehicle after such device
or element of design has been removed
or rendered inoperative by any person.
1-10

CONTROLS
LOCATION OF PARTS ............................................................................................................................... 2-2 2

KEY ............................................................................................................................................................. 2-5
IGNITION SWITCH ..................................................................................................................................... 2-5
STEERING LOCK ....................................................................................................................................... 2-7
INSTRUMENT PANEL ................................................................................................................................ 2-8
LEFT HANDLEBAR .................................................................................................................................. 2-19
RIGHT HANDLEBAR ................................................................................................................................ 2-22
FUEL TANK CAP ...................................................................................................................................... 2-26
GEARSHIFT LEVER ................................................................................................................................. 2-28
REAR BRAKE PEDAL ............................................................................................................................. 2-29
HELMET HOLDER .................................................................................................................................... 2-30
SIDE STAND ............................................................................................................................................. 2-31
SIDECASE (VL1500T/BT) ........................................................................................................................ 2-32
2-1

CONTROLS
LOCATION OF PARTS
VL1500B VL1500T/BT
1 Clutch lever 5 Right handlebar switches

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

VL1500B VL1500T/BT
9 Air cleaner G Engine oil filter

0 Spark plug H Footrests
A Ignition switch I Engine oil filler cap
B Tools J Side stand
C Battery and Main fuse K Engine oil drain plug
D Helmet holder L Speed sensor
E Sidecase (VL1500T/BT) M Engine coolant reservoir
F Gearshift lever N Passenger footrests
2-3

VL1500B VL1500T/BT
O Fuses
P Rear brake fluid reservoir
Q Steering lock
R Rear brake light switch
S Rear brake pedal
2-4

KEY IGNITION SWITCH
This motorcycle comes equipped with a The ignition switch has 3 positions:
main ignition key and a spare one. Keep the
spare key in a safe place. “OFF” POSITION
All electrical circuits are cut off. The engine
will not start. The key can be removed.
2-5

“ON” POSITION “P” (Parking) POSITION
The ignition circuit is completed and the When parking the motorcycle, lock the
engine can now be started. The headlight steering and turn the key to the “P” position.
and taillight will automatically be turned on The key can now be removed and the posi-
when the key is in this position. The key can- tion light (if equipped) and taillight will
not be removed from the ignition switch in remain lit. This position is for night time
this position. roadside parking to increase visibility.
NOTE: Start the engine promptly after turn-

ing the key to the “ON” position, or the bat-  WARNING
tery will lose power due to consumption by If the motorcycle falls down due to a slip
the headlight and taillight. or collision, unexpected damage to the
motorcycle could cause the engine to
keep running, which could result in a
fire, or could result in injury from moving
parts such as the rear wheel.
If the motorcycle falls down, turn the

ignition switch off immediately. Ask your
authorized Suzuki dealer to inspect the
motorcycle for unseen damage.
2-6

STEERING LOCK
 WARNING
Moving the motorcycle while the steer-
ing is locked can be hazardous. You
could lose your balance and fall, or you
could drop the motorcycle.
Never attempt to move the motorcycle

when the steering is locked.
Turn the handlebars all the way to the left.

Insert the ignition key into the steering lock
and turn it counterclockwise to lock the
steering.
2-7

INSTRUMENT PANEL SPEEDOMETER 1
The speedometer indicates the road speed
in kilometers per hour and miles per hour.
If the speedometer needle does not point to

zero, follow the procedure below to reset the
speedometer.
FI
E F
1. Press and hold the button 9 and turn on
the ignition switch.
GEAR
A B
2. Hold the button 9 for 3 seconds.
NOTE: Reset procedure, from step 1 to step

2, should be performed within 10 seconds.
2-8

TURN SIGNAL INDICATOR LIGHT “”
2
When the turn signals are being operated
NOTICE
either to the right or to the left, the indicator Riding the motorcycle with the oil pres-
light will blink intermittently. sure indicator light lit can damage the
engine and transmission.
NOTE: If a turn signal light is not operating
properly due to bulb filament or circuit fail- If the oil pressure indicator light comes
ure, the indicator light blinks more quickly to on, indicating low oil pressure, stop the
notify the rider of the existence of a problem. engine immediately. Check the oil level
and add oil if necessary. If there is a
OIL PRESSURE INDICATOR LIGHT “” proper amount of oil and the light still
3 does not go out, have your authorized
This indicator light comes on when the Suzuki dealer or a qualified mechanic
engine oil pressure is below the normal inspect your motorcycle.
operating range.
NEUTRAL INDICATOR LIGHT “N” 4
The green light will come on when the trans-
mission is in neutral. The light will go out
when you shift into any gear other than neu-
tral.
2-9

COOLANT TEMPERATURE INDICATOR
LIGHT “” 5
This indicator light comes on when the cool-
ant temperature indicates more than 120°C
(248°F). When the coolant temperature indi-
cator light comes on, stop the engine and
check the coolant level after engine cools.
FI
E F
GEAR
A B
NOTICE
Riding the motorcycle with the coolant
temperature indicator lit can cause seri-
ous engine damage due to overheating.
If the engine coolant temperature indica-

tor light comes on, stop the engine to let
it cool. Do not run the engine until the
coolant temperature indicator light goes
off.
2-10

FUEL INJECTION SYSTEM INDICATOR
LIGHT “FI” 6 NOTICE
The fuel injection indicator light comes
on to indicate a problem with the fuel
injection system. Riding the motorcycle
with the fuel injection indicator lit can
damage the engine and transmission.
If the fuel injection system fails, the red indi-
cator light 6 comes on and the display indi- If the display indicates “FI” and the red
cates “FI” at the clock display in the following indicator light comes on, have your
two modes; authorized Suzuki dealer or a qualified
mechanic inspect the fuel injection sys-
A. The display 7 in the odometer display tem as soon as possible.
area indicates “FI” intermittently, and the
red indicator light 6 comes on and
remains lit.
B. The display 7 in the odometer display

area indicates “FI” continuously and the
red indicator light 6 blinks while crank-
ing the engine.
The engine may continue to run in mode A,

but the engine will not run in mode B.
2-11

NOTE:
• If the display indicates “FI” intermittently
and the red indicator light comes on and
remains lit, keep the engine running and
bring your motorcycle to an authorized
Suzuki dealer. If the engine stalls, try
restarting the engine after turning the
FI
E F
ignition switch off and on.
• If the display indicates “FI” continuously
and the red indicator light blinks, the
GEAR
A B
engine will not start.
2-12

COMBINATION SYSTEM DISPLAY 7
The display has six functions, clock, odome-
ter, two trip meters, instrument panel light
brightness and gear position. When the igni-
tion switch is turned to the “ON” position, the
When the display indicates “CHEC”, check display indicates the test pattern shown
the following items; below for two seconds. After the test pattern
• Make sure that the engine stop switch is is displayed, the display will show the func-
in the “” position. tion that was displayed the last time that the
• Make sure that the transmission is in ignition switch was turned off.
neutral or the side stand is fully up.
If the display still indicates “CHEC” after

checking the above items, inspect the igni-
tion fuse and the connection of the lead wire GEAR
couplers.
A B
2-13

GEAR
Odometer
FI
E F
GEAR
GEAR
A B
Trip meter A
To change the display, push the button 8.

The display changes in the order below. GEAR
B
Trip meter B
GEAR
Instrument panel light brightness
2-14

Clock
 WARNING The clock has a 12-hour display. Follow the
procedure below to adjust the clock.
Changing the display while riding can be
hazardous. Removing a hand from the 1. Push the buttons, 8 and 9, simulta-
handlebars can reduce your ability to neously for 2 seconds until the hour dis-
control the motorcycle. play blinks.
2. Adjust the hour display by pushing the
Never change the display while riding. button 9.
Keep both hands on the handlebars.
NOTE: When the button 9 is held in the dis-
play advances continuously.
3. Push the button 8 to highlight the

minute display.
4. Adjust the minute display by pushing the
button 9.
5. Push the button 8 to return to the clock
mode.
2-15

Odometer
The odometer registers the total distance
that the motorcycle has been ridden. The
odometer ranges from 0 to 999999.
NOTE: The odometer display locks at

999999 when the total distance exceeds
FI
E F
999999.
GEAR
A B
2-16

Trip Meters Instrument Panel Light Brightness
The two trip meters are resettable odome- Pushing the button 9 will change the instru-
ters. They can register two kinds of dis- ment panel light brightness in 6 steps. The
tances at the same time. For instance, trip brightness indicator indicates brightness
meter A can register the trip distance and from “” (min) to “” (max).
trip meter B can register the distance
between fuel stops. Gear Position Indicator
The gear position indicator indicates gear
To reset a trip meter to zero, push the button position. This indicator displays “0” when the
9 for 2 seconds while the display indicates transmission is in neutral.
the trip meter A, or B, you want to reset.
NOTE: When the display indicates “CHEC”
NOTE: When the trip meter exceeds 9999.9, in the odometer display area, the gear posi-
the trip meter will return to 0.0 and start tion indicator does not indicate a number but
counting again. indicates “–”.
NOTE: The trip meter will be reset to zero

when the battery is removed or battery is
discharged.
2-17

FUEL METER “” 0
The fuel meter indicates the amount of fuel
remaining in the fuel tank. The fuel meter
displays all 5 segments when the fuel tank is
full. The segment comes on when the fuel
level drops below 3.7 L (3.9/3.3 US/Imp qt).
The segment blink when the fuel drops
FI
E F
below 2.0 L (2.1/1.8 US/Imp qt).
NOTE: The fuel meter will not indicate cor-

GEAR
A B
rectly when the motorcycle is placed on the

side stand. Turn the ignition switch to the
“ON” position when the motorcycle is held
upright.
Approximately Approximately
Fuel tank Full
2.0 L 3.7 L
Blink
Fuel gauge
2-18

HIGH BEAM INDICATOR LIGHT “” A LEFT HANDLEBAR
This blue indicator light will come on when
the headlight high beam is turned on.
CLUTCH LEVER 1
The clutch lever is used for disengaging the
drive to the rear wheel when starting the
engine or shifting transmission gears.
Squeezing the lever disengages the clutch.
HEADLIGHT FLASHER SWITCH 2

Press the switch to flash the headlight.
2-19

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

“” or “” position.
DIMMER SWITCH 3
“” position
The headlight low beam and taillight turn on. NOTICE
Sticking tape or placing objects in front
“” position of the headlight can obstruct headlight
The headlight high beam and taillight turn heat radiation. This can result in head-
on. The high beam indicator light also turns light damage.
on.
Do not stick tape on the headlight or
place objects in front of the headlight.
2-20

NOTICE  WARNING
Do not put objects in front of the head- Failure to use the turn signals, and fail-
light or taillight turned on, and do not ure to turn off the turn signals can be
cover with clothes when the motorcycle hazardous. Other drivers may misjudge
is stopped. your course and this may result in an
accident.
This may cause melting of the lens or
damaging of the set object by the heat of Always use the turn signals when you
lens. intend to change lanes or make a turn.
Be sure to turn off the turn signals after
TURN SIGNAL LIGHT SWITCH “” 4 completing the turn or lane change.
Moving the switch to the “” position will
flash the left turn signal. Moving the switch HORN SWITCH “” 5
to the “” position will flash the right turn Press the switch to sound the horn.
signal. The indicator light will also flash
intermittently. To cancel turn signal opera-
tion, push the switch on.
2-21

RIGHT HANDLEBAR
HAZARD WARNING SWITCH “” 6

All four turn signal lights and indicators will ENGINE STOP SWITCH 1
flash simultaneously when the switch is “” position
turned on with the ignition switch in the “ON” The ignition circuit is off. The engine cannot
or “P” position. Use the hazard warning start or run.
lights to warn other traffic during emergency
parking or when your vehicle could other- “” position
wise become a traffic hazard. The ignition circuit is on and the engine can
run.
2-22

FRONT BRAKE LEVER 2 The distance between the throttle grip and
The front brake is applied by squeezing the the front brake lever is adjustable to 5 posi-
brake lever gently toward the throttle grip. tions. To change the position, push the
This motorcycle is equipped with disk brake brake lever forward and turn the adjuster to
system and excessive pressure is not the desired position. When changing the
required to slow the machine down properly. brake lever position, always be sure the
The brake light will come on when the lever adjuster stops in the proper position; a pro-
is squeezed inward. jection of the brake lever pivot should fit into
the depression of the adjuster. This motor-
Front brake lever adjustment cycle is delivered from the factory with its
adjuster set to position 3.
 WARNING
Adjusting the front brake lever position
while riding can be hazardous. Remov-
ing a hand from the handlebars can
reduce your ability to control the motor-
cycle.
Never adjust the front brake lever posi-

tion while riding. Keep both hands on
the handlebars.
2-23

ELECTRIC STARTER SWITCH “” 3
This switch is used for operating the starter
motor. With the ignition switch in the “ON”
position, the engine stop switch in “”, the
clutch disengaged, push the electric starter
switch to operate the starter motor and start
the engine.
NOTE: This motorcycle is equipped with an

interlock system for the ignition circuit and
the starter circuit. The engine can only be
started if:
• The transmission is in neutral and the
clutch is disengaged, or
• The transmission is in gear, the side
stand is fully up and the clutch is disen-
gaged.
NOTE: The headlight will go off when the

electric starter switch is pushed.
2-24

THROTTLE GRIP 4
NOTICE Engine speed is controlled by the position of
the throttle grip. Turn it toward you to
Engaging the starter motor for more increase engine speed. Turn it away from
than five seconds at a time can damage you to decrease engine speed.
the starter motor and wiring harness
from overheating.
Do not engage the starter motor for more

than five seconds at a time. If the engine
does not start after several attempts,
check the fuel supply and ignition sys-
tem. Refer to the TROUBLESHOOTING
section in this manual.
2-25

FUEL TANK CAP Use fresh gasoline when filling up the fuel
tank. Do not use bad gasoline which is con-
taminated with dirt, dust, water or other liq-
uid. Be careful that dirt, dust or water does
not enter the fuel tank when refueling.
NOTE: Place the motorcycle on the side

stand to fill up the fuel tank to specified
18.0 L (4.8/4.0 US/Imp gal).
To open the fuel tank cap, insert the ignition

key into the lock and turn it clockwise. With
the key inserted, lift the cap up with key. To
close the fuel tank cap, push the cap down
firmly with the key in the cap lock.
1 Fuel level
2 Filler neck
2-26

 WARNING  WARNING
If you overfill the fuel tank, fuel may Failure to follow safety precautions
overflow when it expands due to engine when refueling could result in a fire or
heat or heating by the sun. Fuel that cause you to breathe toxic fumes.
overflows can catch fire.
Refuel in a well ventilated area. Make
Stop adding fuel when the fuel level sure the engine is off and avoid spilling
reaches the bottom of the filler neck. fuel on a hot engine. Do not smoke, and
make sure there are no open flames or
sparks in the area. Avoid breathing gas-
oline vapors. Keep children and pets
away when you refuel the motorcycle.
2-27

GEARSHIFT LEVER This motorcycle has a 5-speed transmission
which operates as shown. To shift properly,
squeeze the clutch lever and close the throt-
tle at the same time you operate the gear-
shift lever. Lift the front end of the gear shift
lever or depress the rear end of the gearshift
lever to upshift. Depress the front end of the
gearshift lever to downshift. Neutral is
located between 1st and 2nd gear. When
neutral is desired, depress or lift the lever
halfway between 1st and 2nd gear.
2-28

NOTE: When the transmission is in neutral, REAR BRAKE PEDAL
the green indicator light on the instrument
panel will be lit. However, even though the
light is lit, cautiously and slowly release the
clutch lever to make sure that the transmis-
sion is positively in neutral.
Reduce your road speed before down-shift-

ing. When down-shifting, the engine speed
should be increased before the clutch is
engaged. This will prevent unnecessary
wear on the drive train components and rear
tire. Depressing the rear brake pedal will apply
the rear brake. The brake light will come on
when the rear brake is operated.
2-29

HELMET HOLDER The helmet holder is located on the left side
below the rear seat. Insert the key and turn it
clockwise to open the latch. Hook your hel-
met fastener ring to the latch and turn the
key back to lock the holder.
 WARNING
Riding with a helmet fastened to the hel-
met holder can interfere with rider con-
trol.
VL1500B Never carry a helmet fastened to the hel-
met holder. Fix the helmet securely atop
the seat if you must carry it.
(VL1500T/BT)
NOTE: The tool box is equipped with the
helmet holder wire. Open the tool box by
referring to the TOOLS section.
VL1500T/BT
2-30

SIDE STAND The side stand/ignition interlock system
works as follows:
• If the side stand is down and the trans-
mission is in gear, the engine can not be
started.
• If the engine is running and the transmis-
sion is shifted into gear with the side
stand down, the engine will stop running.
• If the engine is running and the side
stand is put down with the transmission
in gear, the engine will stop running.
This motorcycle is equipped with a side

stand to support the motorcycle when park-
 WARNING
ing. An interlock system is provided to cut off Riding with the side stand incompletely
the ignition circuit when the side stand is retracted can result in an accident when
down and the transmission is in any gear you turn left.
other than neutral.
Check operation of the side stand/igni-
tion interlock system before riding.
Always retract the side stand completely
before starting off.
2-31

SIDECASE (VL1500T/BT)
NOTICE
If you do not take proper precautions
when parking, the motorcycle can fall
over.
Park the motorcycle on firm, level

ground whenever possible. If you must
park on an incline, aim the front of the
motorcycle uphill and put the transmis-
sion into 1st gear to reduce the possibil-
ity of rolling off the side stand.
2-32

To open the sidecase: NOTE:
Insert the ignition key into the lock and turn it • Do not keep valuable items in the side-
counterclockwise to open the lid. case when leaving the motorcycle unat-
tended.
NOTE: • Put articles in a waterproof bag when
• If it is hard to lock or unlock the sidecase keeping the articles in the sidecase
lid with a spare key without a key cover, because the sidecase can get wet with
use a key with a key cover. rain or washing water.
• If the lock is frozen, pour warm water
around the lock to melt the ice.
To close the sidecase:

Close the lid, Insert the ignition key into the
lock and turn it clockwise to lock the lid.
Remove the ignition key.
The sidecase load capacity is 4.5 kg (10

lbs).
2-33

FUEL, OIL AND COOLANT RECOMMENDATIONS
FUEL OCTANE RATING ............................................................................................................................ 3-2

OXYGENATED FUEL RECOMMENDATION ............................................................................................. 3-3
ENGINE OIL ................................................................................................................................................ 3-5 3
FINAL GEAR OIL ........................................................................................................................................ 3-7
ENGINE COOLANT SOLUTION ................................................................................................................ 3-8
3-1

FUEL, OIL AND COOLANT NOTE: If the engine develops some trouble
like lack of acceleration or insufficiency of its
RECOMMENDATIONS power, the cause may be due to the fuel the
motorcycle uses. In such case, try changing
FUEL OCTANE RATING the gas station to another. If the situation will
Use unleaded gasoline with an octane rating not be improved by changing, consult your
of 91 or higher (Research method). Suzuki dealer for its inspection.
Unleaded gasoline can extend spark plug
life and exhaust components life.
(Canada)
Your motorcycle requires unleaded gasoline
with a minimum pump octane rating of 87
((R+M)/2 method). In some areas, the only
fuels that are available are oxygenated
fuels.
3-2

OXYGENATED FUEL RECOMMENDATION Gasoline/Ethanol Blends
(Canada, EU) Blends of unleaded gasoline and ethanol
Oxygenated fuels which meet the minimum (grain alcohol), also known as “GASOHOL”,
octane requirement and the requirements may be used in your motorcycle if the etha-
described below may be used in your motor- nol content is not greater than 10%.
cycle without jeopardizing the New Vehicle
Limited Warranty or the Emission Control Gasoline/Methanol Blends
System Warranty. Fuels containing 5% or less methanol (wood
alcohol) may be suitable for use in your
NOTE: Oxygenated fuels are fuels which motorcycle if they contain co-solvents and
contain oxygen-carrying additives such as corrosion inhibitors.
MTBE or alcohol.
DO NOT USE fuels containing more than
Gasoline containing MTBE 5% methanol under any circumstances.
Unleaded gasoline containing MTBE Fuel system damage or motorcycle perfor-
(Methyl Tertiary Butyl Ether) may be used in mance problems resulting from the use of
your motorcycle if the MTBE content is not such fuels are not the responsibility of
greater than 15%. This oxygenated fuel Suzuki and may not be covered under the
does not contain alcohol. New Vehicle Limited Warranty or the Emis-
sion Control System Warranty.
3-3

NOTE:
• To help minimize air pollution, Suzuki
recommends that you use oxygenated
NOTICE
fuels. Spilled gasoline containing alcohol can
• Be sure that any oxygenated fuel you damage the painted surfaces of your
use has recommended octane ratings. motorcycle.
• If you are not satisfied with the drivability
of your motorcycle when you are using Be careful not to spill any fuel when fill-
an oxygenated fuel, or if engine pinging ing the fuel tank. Wipe spilled gasoline
is experienced, substitute another brand up immediately.
as there are differences between brands.
NOTICE
Do not use leaded gasoline.
Use of leaded gasoline causes the cata-

lytic converter to malfunction.
3-4

ENGINE OIL SAE Engine Oil Viscosity
Use Suzuki genuine engine oil or equivalent. Suzuki recommends the use of SAE 10W-
If Suzuki genuine engine oil is not available, 40 engine oil. If SAE 10W-40 engine oil is
select a proper engine oil according to the not available, select an alternative according
following guideline. to the following chart.
Oil quality is a major contributor to your
engine’s performance and life. Always select
good quality engine oil. Use oil with an API
(American Petroleum Institute) classifica-
tion of SG, SH, SJ or SL with a JASO classi-
fication of MA.
SAE API JASO

SG, SH, SJ or
10W-40 MA
SL
API: American Petroleum Institute

JASO: Japanese Automobile Standards
Organization
3-5

JASO T903 Energy Conserving
The JASO T903 standard is an index to Suzuki does not recommend the use of
select engine oils for 4-stroke motorcycle “ENERGY CONSERVING” or “RESOURCE
and ATV engines. Motorcycle and ATV CONSERVING” oils. Some engine oils
engines lubricate clutch and transmission which have an API classification of SH, SJ
gears with engine oil. JASO T903 specifies or SL have an “ENERGY CONSERVING”
performance requirements for motorcycle indication in the API classification donut
and ATV clutches and transmissions. mark. These oils can affect engine life and
clutch performance.
There are two classes, MA and MB. The oil
container shows the classification as fol-
lows.
1 Code number of oil sales company

2 Oil classification
3-6

API SG, SH, SJ or SL FINAL GEAR OIL
Use an SAE90 hypoid gear oil which is rated
SERVICE
PI GL-5 under the API classification system. If
SJ
A
SAE you operate the motorcycle where ambient

10W-40 temperature is below 0°C (32°F), use an
SAE80 hypoid gear oil.
Recommended
API SH, SJ or SL
SERVICE
PI
SJ
A
SAE
10W-40
ENE
NG
VI
GY
R
R
CONSE
Not recommended
3-7

ENGINE COOLANT SOLUTION
Use “SUZUKI SUPER LONG LIFE COOL- WARNING
ANT” or “SUZUKI LONG LIFE COOLANT”.
If “SUZUKI SUPER LONG LIFE COOLANT” Engine coolant is harmful or fatal if swal-
and “SUZUKI LONG LIFE COOLANT” are lowed or inhaled. Solution can be poi-
not available, use a glycol-based antifreeze sonous to animals.
compatible with an aluminum radiator mixed
with distilled water only at the ratio of 50:50. Do not drink antifreeze or coolant solu-
tion. If swallowed, do not induce vomit-
ing. Immediately contact a poison
control center or a physician. Avoid
inhaling mist or hot vapors; if inhaled,
remove to fresh air. If coolant gets in
eyes, flush eyes with water and seek
medical attention. Wash thoroughly after
handling. Keep out of the reach of chil-
dren and animals.
3-8

SUZUKI SUPER LONG LIFE COOLANT
NOTICE (Blue)
“SUZUKI SUPER LONG LIFE COOLANT” is
Spilled engine coolant can damage the pre-mixed to the proper ratio. Add only
painted surfaces of your motorcycle. “SUZUKI SUPER LONG LIFE COOLANT” if
coolant level drops. It is not necessary to
Be careful not to spill any fluid when fill- dilute “SUZUKI SUPER LONG LIFE COOL-
ing the radiator. Wipe spilled engine ANT” when replacing coolant.
coolant up immediately.
Engine coolant
Engine coolant performs as a rust inhibitor
and water pump lubricant as well as an anti-
freeze solution. Therefore engine coolant
should be used at all times even though the
atmospheric temperature in your area does
not go down to the freezing point.
3-9

SUZUKI LONG LIFE COOLANT
(Green)
Water for mixing

Use distilled water only. Water other than
distilled water can corrode and clog the alu-
minium radiator.
Required amount of water/coolant

Solution capacity (total): 2700 ml
(2.9/2.4 US/Imp. qt)
1350 ml
Water
(1.4/1.2 US/Imp. qt)
50%
1350 ml
Coolant
(1.4/1.2 US/Imp. qt)
NOTE: This 50% mixture will protect the

cooling system from freezing at tempera-
tures above –31°C. If the motorcycle is to be
exposed to temperature below –31°C, this
mixing ratio should be increased up to
55% (–40°C) or 60% (–55°C) coolant. The
mixing ratio should not exceed 60% coolant.
3-10

BREAK-IN (RUNNING-IN) AND
INSPECTION BEFORE RIDING
MAXIMUM THROTTLE OPENING RECOMMENDATION ......................................................................... 4-2

VARY THE ENGINE SPEED ...................................................................................................................... 4-2
BREAKING IN THE NEW TIRE .................................................................................................................. 4-3
AVOID CONSTANT LOW SPEED .............................................................................................................. 4-3
ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ................................................................ 4-4 4
OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE ..................................................................... 4-4
INSPECTION BEFORE RIDING ................................................................................................................. 4-5
4-1

BREAK-IN (RUNNING-IN) AND VARY THE ENGINE SPEED
INSPECTION BEFORE RIDING The engine speed should be varied and not
held at a constant speed. This allows the
parts to be “loaded” with pressure and then
The opening explains how important proper
unloaded, allowing the parts to cool. This
break-in is to achieve maximum life and per-
aids the mating process of the parts. It is
formance from your new Suzuki. The follow-
essential that some stress be placed on the
ing guidelines explain proper break-in
engine components during break-in to
procedures.
ensure this mating process. Do not, though,
apply excessive load on the engine.
MAXIMUM THROTTLE OPENING
RECOMMENDATION
This table shows the maximum recom-
mended throttle opening during the break-in
period.
800 km Less than

Initial
(500 miles) 1/2 throttle
1600 km Less than
Up to
(1000 miles) 3/4 throttle
4-2

BREAKING IN THE NEW TIRE AVOID CONSTANT LOW SPEED
New tires need proper break-in to assure Operating the engine at constant low speed
maximum performance, just as the engine (light load) can cause parts to glaze and not
does. Wear in the tread surface by gradually seat in. Allow the engine to accelerate freely
increasing your cornering lean angles over through the gears without exceeding the
the first 160 km (100 miles) before attempt- recommended maximum limits. Do not,
ing maximum performance. Avoid hard however, use full throttle for the first 1600
acceleration, hard cornering, and hard brak- km (1000 miles).
ing for the first 160 km (100 miles).
 WARNING
Failure to perform break-in of the tires
could cause tire slip and loss of control.
Use extra care when riding on new tires.

Perform proper break-in of the tires as
described in this section and avoid hard
acceleration, hard cornering, and hard
braking for the first 160 km (100 miles).
4-3

ALLOW THE ENGINE OIL TO CIRCULATE OBSERVE YOUR FIRST AND
BEFORE RIDING MOST CRITICAL SERVICE
Allow sufficient idling time after warm or cold The initial service (1000 km maintenance) is
engine startup before applying load or rev- the most important service your motorcycle
ving the engine. This allows time for the will receive. During break-in operation, all of
lubricating oil to reach all critical engine the engine components will have mated
components. together and seated. Maintenance required
as part of the initial service includes correc-
tion of all adjustments, tightening of all fas-
teners and replacement of dirty oil. Timely
performance of this service will help make
sure you get a best service life and perfor-
mance from the engine.
NOTE: The 1000 km (600 miles) service

should be performed as outlined in the
INSPECTION AND MAINTENANCE section
of this Owner’s Manual. Pay particular atten-
tion to the CAUTION and WARNING in that
section.
4-4

INSPECTION BEFORE RIDING
 WARNING
 WARNING If you operate this motorcycle with
Failure to inspect your motorcycle improper tires or improper or uneven tire
before riding and to properly maintain pressure, you may lose control of the
your motorcycle increases the chances motorcycle. This will increase your risk
of an accident or equipment damage. of an accident.
Always inspect your motorcycle each Always use tires of the size and type
time you use it to make sure it is in safe specified in this owner’s manual. Always
operating condition. Refer to the maintain proper tire pressure as
INSPECTION AND MAINTENANCE sec- described in the INSPECTION AND
tion in this owner’s manual. MAINTENANCE section.
4-5

Before riding the motorcycle, be sure to
WHAT TO CHECK CHECK FOR:
check the following items. Never underesti-
mate the importance of these checks. Per- Steering • Smoothness
form all of them before riding the machine. • No restriction of movement
• No play or looseness
WARNING
Throttle • Correct play in the throttle cable
( 6-38) • Smooth operation and
positive return of the
Checking maintenance items when the throttle grip to the closed
engine is running can be hazardous. You position
could be severely injured if your hands Clutch • Correct lever play
or clothing get caught in moving engine ( 2-19, 6-42) • Smooth and sure action of
clutch lever
parts.
Brakes • Proper pedal and lever
Shut the engine off when performing ( 2-23, 2-29 operation
6-49) • Fluid level in the reservoir to be
maintenance checks, except when above “LOWER” line
checking the lights, engine stop switch, • No fluid leakage
and throttle. • Brake pads not to be worn down
to the limit line
• Correct pedal and lever play
• No “sponginess”
Suspensions Smooth movement
Fuel Enough fuel for the planned
( 2-18) distance of operation
Fuel tank Tank cap locked securely
( 2-26)
4-6

Tires • Correct pressure
( 6-57) • Adequate tread depth
• No cracks or cut
Engine oil Correct level
( 6-30)
Cooling system • Proper coolant level
( 6-44) • No leaks or damage
Gear oil Correct level
( 6-47)
Horn Correct function
( 2-21)
Engine stop switch Correct function
( 2-22)
Lighting Operation of all lights and
( 2-5, 2-8, indicators
2-19)
Side stand/ Proper operation
Ignition interlock
system
( 6-63)
Windshield Good visibility
(VL1500T/BT)
( 8-8)
4-7

RIDING TIPS
STARTING THE ENGINE ........................................................................................................................... 5-2

STARTING OFF .......................................................................................................................................... 5-4
USING THE TRANSMISSION .................................................................................................................... 5-6
RIDING ON HILLS ...................................................................................................................................... 5-8
STOPPING AND PARKING ........................................................................................................................ 5-8
CARRYING A PASSENGER .................................................................................................................... 5-12
5
5-1

RIDING TIPS NOTE: The fuel supply system stops the
engine when the motorcycle is overturned.
Turn off the ignition switch before restarting
STARTING THE ENGINE the engine.
Before attempting to start the engine make
sure: When the engine is cold:
• The transmission is in neutral. 1. Close the throttle completely.
• The engine stop switch is in the “” 2. Squeeze the clutch lever and push the
position. electric starter switch.
3. After the engine starts, let the engine run
NOTE: This motorcycle is equipped with until the engine sufficiently warms up.
interlock system for the ignition circuit and
the starter circuit. The engine can only be When the engine is warm:
started if: Close the throttle completely and push the
• The transmission is in neutral and the electric starter switch.
clutch is disengaged, or
• The transmission is in gear, the side
stand is fully up and the clutch is disen-
gaged.
5-2

When the engine is hard to start:
Open the throttle 1/8 to 1/4 turn and push
the electric starter switch.
NOTICE
Running the engine too long without
riding may cause the engine to overheat.
 WARNING Overheating can result in damage to
Exhaust gas contains carbon monoxide, internal engine components and discol-
a dangerous gas that is difficult to detect oration of exhaust pipes.
because it is colorless and odorless.
Breathing carbon monoxide can cause Shut the engine off if you cannot begin
death or severe injury. your ride promptly.
Never start the engine or let it run

indoors or where there is little or no ven-
tilation.
5-3

STARTING OFF
 WARNING
 WARNING If you remove even one hand or foot
Riding at excessive speeds increases from the motorcycle, you can reduce
your chances of losing control of the your ability to control the motorcycle.
motorcycle, which can result in an acci- This could cause you to lose your bal-
dent. ance and fall off the motorcycle. If you
remove a foot from a footrest, your foot
Always ride at a speed that is proper for or leg may come in contact with the rear
the terrain, visibility and operating con- wheels. This could injure you or cause
ditions, and your skills and experience. an accident.
Always keep both hands on the handle-

bars and both feet on the footrests of
your motorcycle during operation.
5-4

After moving the side stand to the fully up
 WARNING position, squeeze the clutch lever in and
pause momentarily. Engage first gear by
Sudden side winds, which can occur depressing the gearshift lever downward.
when being passed by larger vehicles, at Turn the throttle grip a little toward you and
tunnel exits or in hilly areas, can cause at the same time release the clutch lever
you to lose control of the motorcycle. gently and smoothly. As the clutch engages,
the motorcycle will start moving forward. To
Reduce your speed and be alert to the shift to the next higher gear, accelerate gen-
possibility of sudden side winds. tly, then close the throttle and squeeze the
clutch lever in simultaneously. Lift the gear-
shift lever upward to select the next gear
and release the clutch lever and open the
throttle again. Select higher gears in this
manner until top gear is reached.
NOTE: This motorcycle is equipped with a

side stand/ignition interlock system. If you
shift the transmission into gear when the
side stand is down the engine will stop run-
ning.
5-5

USING THE TRANSMISSION Shifting up schedule
The transmission is provided to keep the
engine operating smoothly in its normal Gear position km/h miles/h
operating speed range. The gear ratios have 1st → 2nd 20 12
been carefully chosen to meet the charac- 2nd → 3rd 30 19
teristics of the engine. The rider should
always select the most suitable gear for the 3rd → 4th 40 25
prevailing conditions. Never slip the clutch to 4th → 5th 50 31
control road speed, but rather downshift to
allow the engine to run within its normal
operational range. Shifting down schedule
(Canada) Gear position km/h miles/h

The table below shows the approximate 5th → 4th 40 25
speed range for each gear
4th → 3rd 30 19
Disengage the clutch when the motorcycle

speed drops below 20 km/h (12 miles/h).
5-6

Downshifting when engine speed is too Downshifting while the motorcycle is
high can; leaned over in a corner may cause rear
• cause the rear wheel to skid and lose wheel skid and loss of control.
traction due to increased engine brak-
ing, resulting in an accident; or Reduce your speed and downshift
• force the engine to overrev in the before entering a corner.
lower gear, resulting in engine dam-
age.
NOTICE
Reduce speed before downshifting.
Improper gearshift lever operation can
damage the transmission.
• Do not rest your foot on the gearshift

lever.
• Do not use force to shift gears.
5-7

RIDING ON HILLS STOPPING AND PARKING
• When climbing steep hills, the motorcy- 1. Turn the throttle grip away from you to
cle may begin to slow down and show close the throttle completely.
lack of power. At this point you should 2. Apply the front and rear brakes evenly
shift to a lower gear so that the engine and at the same time.
will again be operating in its normal 3. Downshift through the gears as road
power range. Shift rapidly to prevent the speed decreases.
motorcycle from losing momentum. 4. Select neutral with the clutch lever
• When riding down a steep hill, the squeezed towards the grip (disengaged
engine may be used for braking by shift- position) just before the motorcycle
ing to a lower gear. stops. The neutral position can be con-
• Be careful, however, not to allow the firmed by observing the neutral indicator
engine to overrev. light.
5-8

Inexperienced riders tend to underuti- Hard braking on wet, loose, rough, or
lize the front brake. This can cause other slippery surfaces can cause wheel
excessive stopping distance and lead to skid and loss of control.
a collision. Using only the front or rear
brake can cause skidding and loss of Brake lightly and with care on slippery or
control. irregular surfaces.
Apply both brakes evenly and at the

same time.  WARNING
Following another vehicle too closely
 WARNING can lead to a collision. As vehicle
speeds increase, stopping distance
Hard braking while turning may cause increases progressively.
wheel skid and loss of control.
Always maintain a safe stopping dis-
Brake before you begin to turn. tance between you and the vehicle in
front of you.
5-9

5. Park the motorcycle on a firm, flat sur-
NOTICE face where it will not fall over.
Holding the motorcycle stopped with

throttle and clutch lever operation on  CAUTION
inclines can damage motorcycle’s A hot muffler can cause severe burns.
clutch. The muffler will be hot enough to cause
burns for some time after stopping the
Use the brakes when stopping the engine.
motorcycle on inclines.
Park the motorcycle where pedestrians
or children are not likely to touch the
muffler.
5-10

NOTE: If the motorcycle is to be parked on 6. Turn the ignition switch to the “OFF”
the side stand on a slight slope, the front position.
end of the motorcycle should face “up” the 7. Turn the handlebars all the way to the
incline to avoid rolling forward off the side left and lock the steering for security.
stand. You may leave the motorcycle in 1st 8. Remove the keys.
gear to help prevent it from rolling off the
side stand. Shift to neutral before starting NOTE: If an optional anti-theft lock such as
the engine. a U-shape lock, brake disk lock or chain is
used to avoid theft, be sure to remove anti-
theft lock before moving the motorcycle.
5-11

CARRYING A PASSENGER To help prevent burn injuries, warn your pas-
Before you invite someone to be a passen- senger not to contact the muffler when
ger on your motorcycle, you need to be thor- mounting or dismounting your motorcycle.
oughly familiar with motorcycle operation.
Adjust tire pressures and suspension
according to the Tire Pressure and Loading
section and the Suspension section of this
manual.
The passenger should always hold onto

your waist or hips, or onto the seat strap or
grab bar, as equipped. Ask your passenger
not to make any sudden movements. When
you lean going around a corner, the passen-
ger should lean with you. The passenger
should always keep his or her feet on the
footrests, even when you are stopped at a
light.
5-12

INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE ..................................................................................................................... 6-2

TOOLS ........................................................................................................................................................ 6-9
LUBRICATION POINTS ........................................................................................................................... 6-10
BATTERY .................................................................................................................................................. 6-11
AIR CLEANER .......................................................................................................................................... 6-17
SPARK PLUGS ......................................................................................................................................... 6-25
ENGINE OIL .............................................................................................................................................. 6-30
THROTTLE CABLE ADJUSTMENT ........................................................................................................ 6-38
ENGINE IDLE SPEED INSPECTION ....................................................................................................... 6-40 6
FUEL HOSE .............................................................................................................................................. 6-40
CLUTCH ADJUSTMENT .......................................................................................................................... 6-42
COOLANT ................................................................................................................................................. 6-44
FINAL GEAR OIL ...................................................................................................................................... 6-47
BRAKES ................................................................................................................................................... 6-49
TIRES ........................................................................................................................................................ 6-57
SIDE STAND/IGNITION INTERLOCK SYSTEM ...................................................................................... 6-63
FRONT WHEEL REMOVAL ..................................................................................................................... 6-64
REAR WHEEL REMOVAL ....................................................................................................................... 6-67
LIGHT BULB REPLACEMENT ................................................................................................................ 6-72
FUSES ....................................................................................................................................................... 6-80
CATALYTIC CONVERTER ....................................................................................................................... 6-82
6-1

INSPECTION AND
MAINTENANCE  WARNING
Improper maintenance or failure to per-
MAINTENANCE SCHEDULE form recommended maintenance can
The chart indicates the intervals between lead to an accident.
periodic services in miles, kilometers and
months. At the end of each interval, be sure Keep your motorcycle in good condition.
to inspect, check, lubricate and service as Ask your Suzuki dealer or a qualified
instructed. If your motorcycle is used under mechanic to perform the maintenance
high stress conditions such as continuous items marked with an asterisk (*). You
full throttle operation, or is operated in a may perform the unmarked mainte-
dusty climate, certain services should be nance items by referring to the instruc-
performed more often to ensure reliability of tions in this section, if you have
the machine as explained in the mainte- mechanical experience. If you are not
nance section. Your authorized Suzuki sure how to do any of the jobs, ask your
dealer can provide you with further guide- Suzuki dealer to do the maintenance.
lines. Steering components, suspension and
wheel components are key items and
require very special and careful servicing.
For maximum safety we suggest that you
have these items inspected and serviced by
your authorized Suzuki dealer or a qualified
service mechanic.
6-2

 WARNING NOTICE
Exhaust gas contains carbon monoxide, Poorly-made replacement parts can
a dangerous gas that is difficult to detect cause your motorcycle to wear more
because it is colorless and odorless. quickly and may shorten its useful life.
Breathing carbon monoxide can cause
death or severe injury. When replacing parts on your vehicle,
use only genuine Suzuki replacement
Never start the engine or let it run parts or their equivalent.
indoors or where there is little or no ven-
tilation. NOTE: The MAINTENANCE CHART speci-
fied the minimum requirements for mainte-
nance. If you use your motorcycle under
NOTICE severe conditions, perform maintenance
Servicing electric parts with the ignition more often than shown in the chart. If you
switch in the “ON” position can damage have any questions regarding maintenance
the electric parts when the electric cir- intervals, consult your Suzuki dealer or a
cuit is shorted. qualified mechanic.
Turn off the ignition switch before servic-

ing the electric parts to avoid short-cir-
cuit damage.
6-3

MAINTENANCE CHART
Interval: This interval should be judged by number of months or odometer reading, whichever
comes first.
Interval months 2 12 24 36 48
km 1000 6000 12000 18000 24000
Item miles 600 4000 7500 11000 14500
– – – I –
Air cleaner element ( 6-17)
Replace every 36000 km (22000 miles)
* Exhaust pipe bolts and muffler bolts T – T – T
* Valve clearance I – I – I
Spark plugs ( 6-25) – I R I R
Fuel hose ( 6-40) – I I I I
Engine oil ( 6-30) R R R R R
Engine oil filter ( 6-30) R – – R –
Throttle cable play ( 6-38) I I I I I
* PAIR (air supply) system – – I – I
* Throttle valve synchronization – – I – I
“SUZUKI SUPER LONG LIFE
Replace every 4 years or 48000 km (29000 miles)
COOLANT” (Blue)
* Engine coolant “SUZUKI LONG LIFE COOL-
( 6-44) ANT” (Green) or an engine cool-
– – R – R
ant other than “SUZUKI SUPER
LONG LIFE COOLANT” (Blue)
6-4

km 1000 6000 12000 18000 24000
Item miles 600 4000 7500 11000 14500
* Radiator hose ( 6-46) – I I I I
Final gear oil ( 6-47) R – I – I
Clutch cable play ( 6-42) – I I I I
* Brakes ( 6-49) I I I I I
– I I I I
Brake hose ( 6-49)
* Replace every 4 years
– I I I I
Brake fluid ( 6-50)
Tires ( 6-57) – I I I I
* Steering I – I – I
* Front forks – – I – I
* Rear suspension – – I – I
* Chassis bolts and nuts T T T T T
Lubrication ( 6-10) Lubricate at every 1000 km (600 miles)
NOTE: I= Inspect and clean, adjust, replace or lubricate as necessary,

R= Replace, T= Tighten
6-5

For Europe and Oceania countries
km 1000 12000 24000 36000 48000
Item miles 600 7500 15000 22500 30000
– – – I –
Air cleaner element ( 6-17)
Replace every 36000 km (22000 miles)
* Exhaust pipe bolts and muffler bolts T T T T T
* Valve clearance I Inspect every 12000 km (7500 miles)
Spark plugs ( 6-25) – R R R R
Fuel hose ( 6-40) – I I I I
Engine oil ( 6-30) R R R R R
Engine oil filter ( 6-30) R – R – R
Throttle cable play ( 6-38) I I I I I
* PAIR (air supply) system – – I – I
* Throttle valve synchronization – I I I I
“SUZUKI SUPER LONG LIFE
– – – – R
COOLANT” (Blue)
* Engine coolant “SUZUKI LONG LIFE COOL-
( 6-44) ANT” (Green) or an engine cool-
– – R – R
ant other than “SUZUKI SUPER
LONG LIFE COOLANT” (Blue)
6-6

km 1000 12000 24000 36000 48000
Item miles 600 7500 15000 22500 30000
* Radiator hose ( 6-46) – I I I I
Final gear oil ( 6-47) R – I – I
Clutch cable play ( 6-42) – I I I I
* Brakes ( 6-49) I I I I I
– I I I I
Brake hose ( 6-49)
Inspect every year or 6000 km (4000 miles)
Brake fluid ( 6-50)
*Replace every 2 years
Tires ( 6-57) – I I I I
* Steering I I I I I
* Front forks – I I I I
* Rear suspension – I I I I
* Chassis bolts and nuts T T T T T
Lubrication ( 6-10) Lubricate at every 1000 km (600 miles)
NOTE: I and Inspect= Inspect and clean, adjust, replace or lubricate as necessary;
R= Replace; T= Tighten
6-7

6-8

TOOLS
A tool kit is provided with your motorcycle.
The tool box is located on the left side of the
motorcycle.
1. Unhook the hooks and remove the

cover.
2. To open the tool box, insert the ignition

key into the lock and turn it counterclock-
wise.
6-9

LUBRICATION POINTS
Proper lubrication is important for smooth
and long life of each working part of your
motorcycle and also for safe riding. It is a
good practice to lubricate the machine after
a long rough ride and after it gets wet in the
rain or after washing it. Major lubrication
points are as follows:
NOTICE
Lubricating electrical switches can dam-
age the switches.
Do not apply grease and oil to electrical

switches.
... Grease
6-10

1 Clutch lever pivot BATTERY
2 Gearshift link pivots The battery on this motorcycle is a sealed
3 Side stand pivot and spring hook type battery and requires no maintenance of
4 Brake lever pivot fluid level and specific gravity. But have your
5 Throttle cable authorized Suzuki dealer check the charging
6 Brake pedal pivot condition of the battery periodically.
The standard charging rate is 1.8A × 5 to 10

hours and the maximum rate is 9.0A × 1
hour.
 WARNING
Battery posts, terminals, and related
accessories contain lead and lead com-
pounds. Lead is harmful to your health if
it gets into your blood stream.
Wash hands after handling any parts

containing lead.
6-11

 WARNING NOTICE
Diluted sulfuric acid from the battery can Exceeding the maximum charging rate
cause blindness or severe burns. for the battery can shorten its life.
When working near the battery, use Never exceed the maximum charging
proper eye protection and gloves. Flush rate for the battery.
eyes or body with ample water and get
medical care immediately if you suffer
injury. Keep batteries out of reach of  WARNING
children.
Wiping the battery with a dry cloth can
cause a static electricity spark, which
 WARNING can start a fire.
Batteries produce flammable hydrogen Wipe the battery with a damp cloth to
gas which can explode if exposed to avoid static electricity build up.
flames or sparks.
Keep flames and sparks away from the

battery. Never smoke when working near
the battery.
6-12

BATTERY REMOVAL
To remove the battery, follow the procedure
below:
1. Place the motorcycle on the side stand.
3. Push down the front end of the rear seat

2 and pull the seat backward.
2. Remove the bolt 1.
6-13

4. Remove the bolts and seat band 3. To 5. Disconnect the negative (–) terminal 5.
remove the front seat 4, raise the rear 6. Remove the cap. Disconnect the positive
end of the front seat and slide it back- (+) terminal 6.
ward. 7. Remove the battery 7.
6-14

To install the battery:
1. Install the battery in the reverse order of
removal.
 WARNING
2. Connect the battery terminals securely. Batteries contain toxic substances
including sulfuric acid and lead. They
could cause injury to humans or could
NOTICE damage the environment.
Reversing the battery lead wires can
damage the charging system and the A used battery must be disposed of or
battery. recycled according to local law and must
not be discarded with ordinary house-
Always attach the red lead to the (+) pos- hold waste. Make sure not to tip over the
itive terminal and the black (or black with battery when you remove it from the
white tracer) lead to the (–) negative ter- vehicle. Otherwise, sulfuric acid could
minal. run out and you might be injured.
NOTE:
• Select the same type MF battery when
replacing the battery.
• Recharge the battery once a month if the
motorcycle is not used for a long time.
6-15

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

located on the battery label indicates that
used battery should be collected separately
from ordinary household waste.
The chemical symbol of “Pb” B indicates
the battery contains more than 0.004% lead.
6-16

AIR CLEANER
If the elements have become clogged with  WARNING
dust, intake resistance will increase with a
resultant decrease in power output and an Operating the engine without the air
increase in fuel consumption. If you use your cleaner element in place can be hazard-
motorcycle under normal low-stress condi- ous. A flame can spit back from the
tions, you should service the air cleaner at engine to the air intake box without the
the intervals specified. If you ride in dusty, air cleaner element to stop it. Severe
wet or muddy conditions, you will need to engine damage can also occur if dirt
inspect the air cleaner element much more enters the engine due to running the
frequently. Use the following procedure to engine without the air cleaner element.
remove the element and inspect it.
Never run the engine without the air
cleaner element in place.
6-17

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

after riding in severe conditions.
Replace the element as necessary. If
water gets in the air cleaner case, imme-
diately clean the element and the inside
of the case.
AIR CLEANER ELEMENT REMOVAL

Remove the fuel tank by referring to the
FUEL HOSE section.
RIGHT
6-18

2. Loosen the clamp bolt.
3. Remove the bolts. Unhook the hook.
4. Remove the air cleaner case 1 with the
joint tube.
LEFT
6-19

5. Remove the screws. Remove the air
cleaner case 2.
RIGHT
LEFT
6-20

6. Remove the screws. Remove the air
cleaner element 3.
RIGHT
LEFT
6-21

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

new one if it is torn. Carefully examine
the air cleaner element for tears during
cleaning.
7. Inspect the air cleaner element condi-
tion. Replace the air cleaner element 8. Reinstall the air cleaner element in
periodically. reverse order of removal. Be sure that
the air cleaner element is securely in
position and is properly sealed.
NOTICE
Compressed air can damage the air
cleaner element.
Do not blow the air cleaner element with

compressed air.
6-22

9. When installing the air cleaner case,
align the marks the air cleaner joint tube
and the air cleaner chamber.
NOTICE
Failure to position the air cleaner ele-
ment properly can allow dirt to bypass
the air cleaner element. This will cause
engine damage.
RIGHT
Be sure to properly install the air cleaner
element.
NOTE: Be careful not to spray water on the

air cleaner box when cleaning the motorcy-
cle.
Reinstall the fuel tank.
NOTE: Check that the fuel tank drain hose

and breather hose are not bent before rein-
LEFT stalling the fuel tank.
6-23

AIR CLEANER DRAIN PLUG
RIGHT
LEFT
6-24

Remove the plug and drain water and oil at SPARK PLUGS
the periodic maintenance interval. The air
cleaner drain plugs are located inside the air SPARK PLUG REMOVAL
cleaner box and air cleaner left chamber 1. Place the motorcycle on the side stand.
side.
6-25

FRONT REAR
6-26

2. Unhook the hooks and pull off the cover. SPARK PLUG INSPECTION
3. Pull off the spark plug caps.
4. Remove the spark plugs with a spark
plug wrench.
0.8 – 0.9 mm
(0.031 – 0.035 in)
Readjust the spark plug gap to 0.8 – 0.9 mm

(0.031 – 0.035 in) with a spark plug gap
thickness gauge. The spark plug should be
replaced every 12000 km (7500 miles).
6-27

Before removing the carbon deposits, PLUG REPLACEMENT GUIDE
observe the color of the porcelain tip of each
spark plug. This color tells you whether or
not the standard spark plug is suitable for NOTICE
your type of usage. A normally-operating An improper spark plug may have an
spark plug should be light brown in color. If incorrect fit or inappropriate heat range
the spark plug is white or glazed appearing for your engine. This may cause severe
then it has been operating much too hot. engine damage which may not be cov-
This spark plug should be replaced with a ered under warranty.
colder plug.
Use one of the spark plugs listed or their
equivalent. Consult your Suzuki dealer if
you are not sure which spark plug is cor-
rect for your type of usage.
6-28

INSTALLATION
NGK DENSO REMARKS
CPR6EA-9 U20EPR9 Standard
If the standard plug is
NOTICE
CPR7EA-9 U22EPR9 apt to overheat, replace Improper installation of the spark plug
with this plug.
can damage your motorcycle. An overly-
tight or cross-threaded spark plug will
NOTE: This motorcycle uses a resistor-type damage the aluminum threads of the cyl-
spark plug to avoid jamming electronic inder head.
parts. Improper spark plug selection may
cause electronic interference with your Carefully turn the spark plug by hand
motorcycle’s ignition system, resulting in into the threads. If the spark plug is new,
motorcycle performance problems. Use only tighten it with a wrench about 1/2 turn
the recommended spark plugs. past finger tight. If you are reusing the
old spark plug, tighten it with a wrench
about 1/8 turn past finger tight.
6-29

ENGINE OIL
NOTICE Long engine life depends much on the
selection of a quality oil and the periodic
Dirt can damage the moving engine changing of the oil. Daily oil level checks and
parts of your motorcycle if it enters an periodic changes are two of the most impor-
open spark plug hole. tant maintenance items to be performed.
Cover the spark plug hole while the ENGINE OIL LEVEL CHECK
spark plug is out of the hole.
L F
6-30

Check the engine oil level with the engine oil The engine oil level inspection should be
dipstick. The dipstick comes out together performed under the following conditions:
with the oil filler cap as shown. The level on
the dipstick should be between the “L” (Low) 1. Place the motorcycle on the side stand.
and “F” (Full) lines. 2. Start the engine and allow it to idle for
about three minutes. If the engine is
 CAUTION cold, warm up the engine sufficiently.
3. Stop the engine and wait approximately
Exhaust pipes can be hot enough to three minutes.
burn you. 4. Remove the oil dipstick and clean the
dipstick.
Use gloves to avoid burns. 5. Hold the motorcycle vertically. Insert the
oil dipstick through the oil filler hole. The
oil filler cap threads should not be run in
but touching should be the filler hole
upper edge.
6. Pull out the oil dipstick and inspect the
oil level.
7. Refit the oil dipstick.
6-31

ENGINE OIL AND FILTER CHANGE
NOTICE Change the engine oil and oil filter at the
scheduled time. The oil should be changed
Operating the motorcycle with too little when the engine is warm so that the oil will
or too much oil can damage the engine. drain thoroughly from the engine. The pro-
cedure is as follows:
Place the motorcycle on level ground.
Check the oil level with the engine oil 1. Place the motorcycle on the side stand.
dipstick before each use of the vehicle.
Be sure the engine oil level is always
above the “L” (low) line and not higher
than the “F” (full) line.
2. Remove the oil filler cap 1.
6-32

 CAUTION
Hot engine oil and exhaust pipes can
burn you.
Wait until the oil drain plug and exhaust

pipes are cool enough to touch with bare
hands before draining oil.
3. Place a drain pan under the drain plug.

4. Remove the drain plug 2 and gasket 3
from the bottom of the engine and drain
the engine oil into a drain pan.
6-33

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

ters away from children and pets. To
minimize your exposure to used oil, wear Oil filter wrench
(Part No. 09915-40620)
a long-sleeve shirt and moisture-proof
gloves (such as dishwashing gloves)
when changing oil. If oil contacts your
skin, wash thoroughly with soap and
water. Launder any clothing or rags if
wet with oil. Recycle or properly dispose
of used oil and filters.
NOTE: Recycle or properly dispose of used

oil.
6-34

5. Turn the oil filter 4 counterclockwise 6. Wipe off the mounting surface 5 on the
and remove it with a Suzuki “cap type” oil engine where the new filter will be
filter wrench or a “strap type” filter seated with a clean rag.
wrench of the proper size.
6-35

8. Screw the new filter by hand until the fil-
ter gasket contacts the mounting surface
(a small resistance will be felt).
NOTE: To tighten the oil filter properly, it is

important to accurately identify the position
at which the filter gasket first contacts the
mounting surface.
7. Smear a little engine oil around the rub-

ber gasket 6 of the new oil filter.
NOTICE
Failure to use an oil filter with the correct
design and thread specifications can
damage your motorcycle’s engine.
Be sure to use a genuine Suzuki oil filter

or an equivalent one designed for your
motorcycle.
6-36

9. Mark the top dead center position on the
“cap type” filter wrench or on the oil filter.
Mark top dead center Use an oil filter wrench to tighten the fil-
ter 2 turns or to specified torque.
Oil filter wrench
Oil filter tightening torque:
20 N·m (2.0 kgf-m, 14.5 lbf-ft)
10. Replace the drain plug gasket 3 with a

new one. Reinstall the drain plug 2 and
In the position at
gasket 3. Tighten the plug securely with
which the filter a torque wrench. Pour about 3200 ml
gasket first contacts (3.4/2.8 US/Imp qt) of the specified oil in
the mounting the filler hole. Tighten the oil filler cap.
surface. Start the engine and allow it to idle for
three minutes.
Drain plug tightening torque:

23 N·m (2.3 kgf-m, 16.5 lbf-ft)
NOTE: About 3000 ml (3.2/2.6 US/Imp qt) of

oil will be required when changing oil only.
Tighten the filter 2 turns or
to specified torque.
6-37

THROTTLE CABLE ADJUSTMENT
NOTICE
Engine damage may occur if you use oil
that does not meet Suzuki’s specifica-
tions.
Be sure to use the oil specified in the

FUEL, OIL AND ENGINE COOLANT REC-
OMMENDATIONS section.
11. Check the oil level according to Oil Level

Check procedure.
NOTE: Check to see that no oil is leaking

from the oil filter cover.
2.0 – 4.0 mm
(0.08 – 0.16 in)
6-38

To adjust the cable play: THROTTLE CABLE BOOTS
1. Loosen the lock nut 1.
2. Turn the adjuster 2 so that the throttle
grip has 2.0 – 4.0 mm (0.08 – 0.16 in)
play.
3. Tighten the lock nut 1.
 WARNING
Inadequate throttle cable play can cause
engine speed to rise suddenly when you
turn the handlebars. This can lead to
loss of control and an accident. The throttle cable has boots. Check that the
boots are fit securely. Do not apply water
Adjust the throttle cable play so that directly to the boots when washing. Wipe off
engine idle speed does not rise due to dirt from the boots with a wet cloth when the
handlebar movement. boots are dirty.
6-39

ENGINE IDLE SPEED INSPECTION FUEL HOSE
Inspect the engine idle speed. The engine
idle speed should be 900 – 1100 r/min when FUEL TANK LIFT
the engine is warm. 1. Place the motorcycle on the side stand.
Remove the seat by referring to the BAT-
NOTE: If the engine idle speed is not within TERY section.
the specified range, ask your Suzuki dealer
or a qualified mechanic to inspect and repair
the motorcycle.
2. Remove the bolts.
6-40

3. Disconnect the coupler 1 and remove 4. Remove the bolt 3. Raise the rear end
the instrument panel assembly 2. of the fuel tank and slide it backward.
6-41

CLUTCH ADJUSTMENT
Clutch cable play should be 10 – 15 mm (0.4
– 0.6 in) measured at the clutch lever end.
Adjust clutch cable play according to the fol-
lowing procedure:
Minor Adjustment
5. Inspect the fuel hose for damage and

fuel leakage. If any defects are found,
the fuel hose must be replaced.
NOTE: Lifting up the fuel tank too much can

result in the fuel hose becoming bent or
twisted. Lift the fuel tank as little as possible 10 – 15 mm
and disconnect the fuel hose. The fuel tank (0.4 – 0.6 in)
in the above illustration is lifted to show the
fuel hose and coupler clearly. Loosen the lock nut 2. Turn the clutch cable
adjuster 1 to provide the specified play.
6-42

Major Adjustment
2. Loosen the lock nuts 3 and turn the

1. Remove the 3 bolts. Remove the cover. nuts to obtain the correct clutch lever
play.
3. Minor adjustment can be made with the
clutch lever side adjuster 1.
4. Tighten the lock nuts 2 and 3.
6-43

NOTE: Check that the clearance between COOLANT
the clutch cable and gearshift rod is more COOLANT LEVEL
than 6 mm (0.2 in) before tightening the lock
nuts 3.
NOTE: Any maintenance of the clutch other

than the clutch cable play adjustment should
be performed by your Suzuki dealer. F
L
The engine coolant solution should be

between the “F” (full) and “L” (low) level lines
on the engine coolant reservoir. If the level is
lower than “L” (low) level line, bring it up to
“F” (full) level by adding specified engine
coolant.
6-44

NOTE:
• Check the coolant level when the engine
is cold.
• If the engine coolant reservoir is empty,
check the radiator coolant level.
To add specified engine coolant:

3. Remove the filler cap and add specified

engine coolant through the filler hole.
2. Remove the bolts and left side lower

cover.
6-45

NOTE: Adding only water will dilute the
 WARNING engine coolant and reduce its effectiveness.
Add specified engine coolant.
Engine coolant is harmful or fatal if swal-
lowed or inhaled. Solution can be poi- CHANGING THE COOLANT
sonous to animals. Change the coolant periodically.
Do not drink antifreeze or coolant solu- NOTE: About 2700 ml (2.9/2.4 US/Imp. pt)
tion. If swallowed, do not induce vomit- of coolant will required when filling the radia-
ing. Immediately contact a poison tor and reservoir tank.
control center or a physician. Avoid
inhaling mist or hot vapors; if inhaled, RADIATOR HOSE INSPECTION
remove to fresh air. If coolant gets in Inspect the radiator hoses for cracks, dam-
eyes, flush eyes with water and seek age or engine coolant leakage. If any
medical attention. Wash thoroughly after defects are found, ask your Suzuki dealer to
handling. Keep out of the reach of chil- replace the radiator hose with a new one.
dren and animals.
6-46

FINAL GEAR OIL 3. Drain the oil by removing the drain plug
Change the gear oil at initial 1000 km (600 2 into a suitable container from the bot-
miles) and inspect every 12000 km (7500 tom of the final gear case while holding
miles). Use SAE90 hypoid gear oil which is the motorcycle vertically.
rated GL-5 under API classification system. 4. Reinstall the drain plug and tighten it
If you operate the motorcycle where ambient securely after all the oil has been
temperature is below 0°C (32°F) use SAE drained out. Pour fresh oil through the
80 hypoid gear oil. The procedure is as fol- filler hole until the oil level reaches the oil
lows: filler hole while holding the motorcycle
vertically. Approximately 200 – 220 ml
1. Place the motorcycle on the side stand. (6.8 – 7.4/7.0 – 7.7 US/Imp oz) of oil will
be required.
5. Reinstall the oil filler cap.
2. Remove the oil filler cap 1.
6-47

Operating the motorcycle with too little Children and pets may be harmed by
final gear oil can cause the final drive swallowing new or used oil. Repeated,
unit to lock up and cause an accident. prolonged contact with used engine oil
may cause skin cancer. Brief contact
Check for leaks and the correct level of with oil may irritate skin.
final gear oil before each use. Add oil if
necessary. Tighten the drain plug Keep new and used oil and used oil fil-
securely after changing the gear oil. ters away from children and pets. To
minimize your exposure to used oil, wear
a long-sleeve shirt and moisture-proof
gloves (such as dishwashing gloves)
when changing oil. If oil contacts your
skin, wash thoroughly with soap and
water. Launder any clothing or rags if
wet with oil. Recycle or properly dispose
of used oil and filters.
NOTE: Recycle or properly dispose of used

oil.
6-48

BRAKES Inspect your brake system for the following
This motorcycle utilizes front and rear disk items daily:
brakes. Proper operation of brake systems • Inspect the fluid level in the reservoirs.
are vital to safe riding. Be sure to perform • Inspect the front and rear brake system
the brake inspection as scheduled. for signs of fluid leakage.
• Inspect the brake hose for leakage or a
BRAKE SYSTEM cracked appearance.
• The brake lever and pedal should have
the proper stroke and be firm at all times.
 WARNING • Check the wear of the disk brake pads.
Failure to properly inspect and maintain
BRAKE HOSE INSPECTION
your motorcycle’s brake systems can
Inspect the brake hoses and hose joints for
increase your chance of having an acci-
cracks, damage or brake fluid leakage. If
dent.
any defects are found, ask your Suzuki
dealer to replace the brake hose with a new
Be sure to inspect the brakes before
one.
each use according to the INSPECTION
BEFORE RIDING section. Always main-
tain your brakes according to the MAIN-
TENANCE SCHEDULE.
6-49

BRAKE FLUID
FRONT
REAR
Check the brake fluid level in both the front

and rear brake fluid reservoirs. Inspect for
brake pad wear and leaks.
6-50

Brake fluid will gradually absorb mois- The use of any fluid except DOT4 brake
ture through the brake hoses. Brake fluid fluid from a sealed container can dam-
with high water content lowers the boil- age the brake system and lead to an
ing point and can cause brake system accident.
malfunction due to corrosion of brake
components. Boiling brake fluid or brake Clean filler cap before removing. Use
system malfunction could result in an only DOT4 brake fluid from a sealed con-
accident. tainer. Never use or mix with different
types of brake fluid.
Replace the brake fluid every two years
to maintain braking performance.
6-51

 WARNING NOTICE
Brake fluid is harmful or fatal if swal- Spilled brake fluid can damage painted
lowed, and harmful if it comes in contact surfaces and plastic parts.
with skin or eyes. Solution can be poi-
sonous to animals. Be careful not to spill any fluid when fill-
ing the brake fluid reservoir. Wipe spilled
If brake fluid is swallowed, do not induce fluid up immediately.
vomiting. Immediately contact a poison
control center or a physician. If brake
fluid gets in eyes, flush eyes with water
and seek medical attention. Wash thor-
oughly after handling. Keep out of the
reach of children and animals.
6-52

BRAKE PADS
Inspect the front and rear brake pads by not-

FRONT ing whether or not the friction pads are worn
down to the grooved wear limit line 1. If a
front or rear pad is worn to the grooved wear
limit line both front or both rear pads must
be replaced with new ones by your autho-
rized Suzuki dealer or qualified service
mechanic.
REAR
6-53

Failure to inspect and maintain the brake If you ride this motorcycle after brake
pads and replace them when recom- system repair or brake pad replacement
mended can increase your chance of without pumping the brake lever/pedal,
having an accident. you may get poor braking performance
which could result in an accident.
If you need to replace brake pads, have
your Suzuki dealer do this work. Inspect After brake system repair or brake pad
and maintain the brake pads as recom- replacement, pump the brake lever/pedal
mended. several times until brake pads are
pressed against the brake disks and
proper lever/pedal stroke and firm feel
are restored.
NOTE: Do not squeeze/depress the brake

lever/pedal when the pads are not in their
positions. It is difficult to push the pistons
back and brake fluid leakage may result.
6-54

REAR BRAKE PEDAL ADJUSTMENT
 WARNING
Replacing only one of the two brake
 CAUTION
pads can result in uneven braking action A hot muffler can burn you. The muffler
and can increase your chance of having will be hot enough to burn you for some
an accident. time after stopping the engine.
Always replace both pads together. Wait until the muffler cools to avoid
burns.
The rear brake pedal position must be prop-

erly adjusted at all times or the disk brake
pads will rub against the disk causing dam-
age to the pads and to the disk surface.
Adjust the brake pedal position in the follow-
ing manner:
6-55

110 – 120 mm 1. Loosen the lock nut 1, and turn the
(4.3 – 4.7 in) push rod 2 to locate the pedal 110 –
120 mm (4.3 – 4.7 in) above the top face
of the footrest.
2. Retighten the lock nut 1 to secure the
push rod 2 in the proper position.
NOTICE
An incorrectly adjusted brake pedal may
force brake pads to rub against the disk
at all times, causing damage to the pads
and disk.
Follow the steps in this section to adjust

the brake pedal properly.
6-56

REAR BRAKE LIGHT SWITCH TIRES
 WARNING
The tires on your motorcycle form the
crucial link between your motorcycle
and the road. Failure to take the precau-
tions below may result in an accident
due to tire failure.
• Check tire condition and pressure

before each ride, and adjust pressure
To adjust the brake light switch, hold the if necessary.
switch body and turn the adjuster so that the • Avoid overloading your motorcycle.
brake light will come on just before a pres- • Replace a tire when worn to the speci-
sure rise is felt when the brake pedal is fied limit, or if you find damage such
depressed. as cuts or cracks.
• Always use the size and type of tires
specified in this owner’s manual.
• Balance the wheel after tire installa-
tion.
• Read this section of the owner’s man-
ual carefully.
6-57

TIRE PRESSURE AND LOADING
 WARNING Proper tire pressure and proper tire loading
are important factors. Overloading your tires
Failure to perform break-in of the tires can lead to tire failure and loss of motorcycle
could cause tire slip and loss of control, control.
which could result in an accident.
Check tire pressure each day before you
Use extra care when riding on new tires. ride, and be sure the pressure is correct for
Perform proper break-in of the tires the motorcycle load according to the follow-
referring to the BREAK-IN section of this ing table. Tire pressure should only be
manual and avoid hard acceleration, checked and adjusted before riding since
hard cornering, and hard braking for the riding will heat up the tires and lead to
first 160 km (100 miles). higher inflation pressure readings.
6-58

Cold tire inflation pressure Under-inflated tires make smooth cornering
difficult, and can result in rapid tire wear.
LOAD
SOLO RIDING
DUAL RIDING Over-inflated tires cause smaller amount of
OR SOLO tire to be in contact with the road, which can
WITH LIGHT OR
RIDING WITH
LITTLE CARGO
HEAVY CARGO
contribute to skidding and loss of control.
LOAD
TIRE LOAD
NOTE: When you detect drops in tire pres-
225 kPa 225 kPa
FRONT 2.25 kgf/cm2 2.25 kgf/cm2 sure, check the tire for nails or other punc-
33 psi 33 psi tures, or a damaged wheel rim. Tubeless
250 kPa 280 kPa
tires sometimes lose pressure gradually
REAR 2.50 kgf/cm2 2.80 kgf/cm2 when punctured.
36 psi 41 psi
6-59

TIRE CONDITION AND TYPE
Proper tire condition and proper tire type
affect motorcycle performance. Cuts or
cracks in the tires can lead to tire failure and
loss of motorcycle control. Worn tires are
susceptible to puncture failures and subse-
quent loss of motorcycle control. Tire wear
also affects the tire profile changing motor-
cycle handling characteristics.
NOTE: The “Triangle mark” indicates the

place where the wear bars are molded into
the tire. When the wear bars contact the
road, it indicates that the tire wear limit has
been reached.
Whenever you replace a tire, use a tire of

Check the condition of your tires each day the size and type listed below. If you use a
before you ride. Replace tires if tires show different size or type of tire, motorcycle han-
visual evidence of damage, such as cracks dling may be adversely affected, possibly
or cuts, or if tread depth is less than 1.6 mm resulting in loss of motorcycle control.
(0.06 in) front, 2.0 mm (0.08 in) rear.
6-60

FRONT
130/80R17M/C
REAR
200/60R16M/C
 WARNING
SIZE
65H 79H An improperly repaired, installed, or bal-
TYPE
BRIDGESTONE BRIDGESTONE anced tire can cause loss of control and
G853 G G852 G an accident, or can wear out sooner.
Always balance the wheel after repairing a • Ask your Suzuki dealer or a qualified
puncture or replacing the tire. Proper wheel mechanic to perform tire repair,
balance is important to avoid variable wheel- replacement, and balancing because
to-road contact, and to avoid uneven tire proper tools and experience are
wear. required.
• Install tires according to the rotation
direction shown by arrows on the side-
wall of each tire.
6-61

 WARNING • Do not use an external repair plug to
repair a puncture since the plug may
Failure to follow the instructions below work loose as a result of the cornering
for tubeless tires may result in an acci- forces experienced by a motorcycle
dent due to tire failure. Tubeless tires tire.
require different service procedures than • After repairing a tire, do not exceed 80
tube tires. km/h (50 mph) for the first 24 hours,
and do not exceed 130 km/h (80 mph)
• Tubeless tires require an air-tight seal thereafter. This is to avoid excessive
between the tire bead and wheel rim. heat build-up which could result in a
Special tire irons and rim protectors or tire repair failure and tire deflation.
a specialized tire mounting machine • Replace the tire if it is punctured in the
must be used for removing and install- sidewall area, or if a puncture in the
ing tires to prevent tire or rim damage tread area is larger than 6 mm (3/16 in).
which could result in an air leak. These punctures cannot be repaired
• Repair punctures in tubeless tires by adequately.
removing the tire and applying an
internal patch.
6-62

SIDE STAND/IGNITION INTERLOCK If the engine stops running when the side
SYSTEM stand is moved to the down position then the
side stand/ignition interlock system is work-
ing properly. If the engine continues to run
with the side stand down and the transmis-
sion in gear, then the side stand/ignition
interlock system is not working properly.
Have your motorcycle inspected by an
authorized Suzuki dealer or a qualified ser-
vice mechanic.
Check the side stand/ignition interlock sys-

tem for proper operation as follows:
1. Sit on the motorcycle in the normal riding
position, with the side stand up.
2. Shift into first gear, hold the clutch in,
and start the engine.
3. While continuing to hold the clutch in,
move the side stand to the down posi-
tion.
6-63

FRONT WHEEL REMOVAL
 WARNING 1. Place the motorcycle on the side stand.
If the side stand/ignition interlock sys-
tem is not working properly, it is possi-
ble to ride the motorcycle with the side
stand in the down position. This may
interfere with rider control during a left
turn and could cause an accident.
Check the side stand/ignition interlock

system for proper operation before
riding. Check that the side stand is
returned to its full up position before
starting off. 2. Loosen the axle holder bolt 1 on the
right front fork. Loosen the axle shaft 2
temporarily.
NOTE: A special tool is necessary to loosen

the axle shaft 2. The special tool is avail-
able from a Suzuki dealer.
6-64

3. Place an accessory service stand or
equivalent under the swingarm to help
stabilize the rear end. Carefully position
a jack under the engine or chassis tubes
and raise the jack until the front wheel is
slightly off the ground.
NOTICE
Improper jacking may cause damage to
the oil filter.
4. Turn the axle counterclockwise and draw
Do not place the jack under the oil filter it out.
when jacking up the motorcycle.
6-65

6. To reinstall the wheel assembly, reverse
the sequence described above.
7. After installing the wheel, apply the front
brake several times to restore the proper
lever stroke.
 WARNING
Failure to extend brake pads after install-
ing the wheel can cause poor braking
performance and may result in an acci-
5. Slide the front wheel forward. dent.
NOTE: Never squeeze the front brake lever Before riding, “pump” the brake lever
with the front wheel removed. It is very diffi- repeatedly until the brake pads are
cult to force brake pads into the caliper pressed against the brake disks and
assembly. proper lever stroke and firm feel are
restored. Also check that the wheel
rotates freely.
6-66

REAR WHEEL REMOVAL
 WARNING
If the bolts and nuts are not properly  CAUTION
tightened, the wheel can come off, caus-
ing an accident. A hot muffler can burn you.
Be sure to tighten the bolts and nuts to Wait until the muffler cools before
the specified torque. If you do not have a removing the axle nut.
torque wrench or do not know how to
use one, ask your authorized Suzuki
dealer to check the bolts and nuts. NOTICE
Removing the rear wheel without use of
Front axle tightening torque: an accessory stand can result in your
100 N·m (10.0 kgf-m, 72.5 lbf-ft) motorcycle falling over and being dam-
aged.
Front axle holder bolt tightening torque:
33 N·m (3.3 kgf-m, 24.0 lbf-ft) Do not attempt roadside removal of the
rear wheel. Only remove the rear wheel
at a properly equipped servicing facility
using an accessory service stand.
6-67

2. (VL1500T/BT) Open the right sidecase

by referring to the SIDECASE section.
Remove the bolts and right sidecase.
3. (VL1500T/BT) Remove the bolts and

sidecase brace 1 and 2.
6-68

4. Remove the cap. 5. Remove the axle nut 3.
 CAUTION
A hot muffler can burn you.
Wait until the muffler cools before

removing the axle nut.
6-69

6. Place an accessory service stand or
equivalent under the swingarm or chas-
sis tubes to stabilize the rear end.
7. Draw out the axle.
8. Remove the brake caliper bracket

mounting bolt 4. Remove the brake cali-
per assembly 5.
6-70

 WARNING
If the bolts and nuts are not properly
tightened, the wheel can come off, caus-
ing an accident.
Be sure to tighten the bolts and nuts to

the specified torque. If you do not have a
torque wrench or do not know how to
use one, ask your authorized Suzuki
9. Remove the wheel from the splined drive dealer to check the bolts and nuts.
gear and set the wheel assembly on the
ground. Rear axle tightening torque:
10. Remove the rear wheel assembly. 100 N·m (10.0 kgf-m, 72.5 lbf-ft)
11. To replace the wheel reverse the com-
plete sequence listed. Rear brake caliper bracket mounting bolt
tightening torque:
94 N·m (9.4 kgf-m, 68.0 lbf-ft)
NOTE: Apply a drop of SUZUKI THREAD

LOCK “1322D” to the rear brake caliper
bracket mounting bolt 4.
6-71

LIGHT BULB REPLACEMENT Headlight 12V 60/55W (H4)
The wattage rating of each bulb is shown on
the chart below. When replacing a burned Front 12V 21W
Turn signal light
out bulb, always use the exact same wattage Rear 12V 21W
rating. Using other than the specified rating Position light
can result in overloading the electrical sys- 12V 5W
(if equipped)
tem or premature failure of a bulb. Licence plate light 12V 5W
NOTICE
Failure to use a light bulb with the cor-
rect wattage rating can overload the
electrical system of your motorcycle or
cause the bulb to burn out sooner.
Use only the light bulbs shown in the

chart as replacement bulbs.
6-72

HEADLIGHT
To replace the headlight bulb, follow the pro-
cedure below:
2. Remove the bolts. Unhook the hooks.

Remove the headlight assembly 2.
1. Remove the right and left bolts. Unhook

the hooks. Remove the headlight cover
1.
6-73

3. Disconnect the socket 3 from the head- 4. Unhook the bulb holder spring 5, and
light and remove the rubber cap 4. pull out the bulb 6.
6-74

POSITION LIGHT
NOTICE (if equipped)
The headlight bulb’s life may be short-

ened by oil from your fingers if you
touch it.
When replacing the headlight bulb, be

careful not to touch the glass. Grasp the
new bulb with a clean cloth.
5. To replace the headlight bulb, reverse

the above sequence.
1. Pull out the socket.
6-75

HEADLIGHT BEAM ADJUSTMENT
The headlight beam can be adjusted both
up and down or right and left if necessary.
2. Pull off the bulb from the socket.
To adjust the beam up and down:

Turn the adjuster 1 clockwise or counter-
clockwise.
6-76

TURN SIGNAL LIGHTS
To replace the turn signal light bulbs, follow
the procedure below:
To adjust the beam right and left:

Turn the adjuster 2 clockwise or counter-
clockwise.
1. Remove the screw 1.
2. Turn the lens counterclockwise and
remove it.
6-77

NOTICE
Overtightening the screws when rein-
stalling the lens may cause the lens to
crack.
Tighten the screws only until they are

snug.
3. Push in on the bulb 2, turn it to the left

and pull it out.
4. To fit the replacement bulb, push it in and
turn it to the right while pushing.
6-78

LICENSE PLATE LIGHT
To replace the license plate light bulb, follow
the procedure steps:
2. Pull off the bulb from the socket.
1. Turn the license plate lens counterclock-

wise and remove it.
6-79

FUSES
If something electrical on your motorcycle WARNING
stops working, the first thing you should
check for is a blown fuse. The electrical cir- Replacing a fuse with incorrect amper-
cuits on the motorcycle are protected from age rating or substitute, e.g. aluminum
overload by fuses in the circuits. foil or wire, may cause serious damage
to the electrical system and possibly
If a blown fuse is found, then the electrical fire. Always replace a blown fuse with a
problem must be inspected and repaired fuse of the same amperage rating.
before replacing the blown fuse with a new
fuse. Consult your Suzuki dealer for the If the new fuse blows in a short time, the
electrical system check and repair. electrical problem may not be fixed.
Have your motorcycle inspected immedi-
ately by your Suzuki dealer.
6-80

MAIN FUSE FUSES
The main fuse is located under the front The fuses are located under the front seat.
seat. One 30A spare fuse is located in the Two spare fuses (10A and one 15A) are pro-
fuse box. vided in the fuse box.
6-81

FUSE LIST CATALYTIC CONVERTER
• 30A MAIN fuse protects all electrical cir- The purpose of the catalytic converter is to
cuits. minimize the amount of harmful pollutants in
• 10A HEAD-HI fuse protects the speed- your motorcycle’s exhaust. Use of leaded
ometer and headlight high beam. fuel in motorcycles equipped with catalytic
• 10A HEAD-LO fuse protects the head- converters is prohibited because lead deac-
light low beam. tivates the pollutant-reducing components of
• 15A IGNITION fuse protects the head- the catalyst system.
light relay, fan motor relay, side stand
relay, oxygen sensor, solenoid, ECU, fuel The converter is designed to last the life of
pump relay, starter relay and ignition the motorcycle under normal usage and
coils. when unleaded fuel is used. Not special
• 10A SIGNAL fuse protects the pilot maintenance is required on the converter.
lamp, horn, speedometer, turn signal However, it is very important to keep the
light, license light, stop lamp, taillight and engine properly tuned. Engine misfiring,
position light (if equipped). which can result from an improperly tuned
• 10A FUEL fuse protects the ECU, fuel engine, may cause overheating of the cata-
pump, injectors and speedometer. lyst. This may result in permanent heat dam-
• 15A FAN fuse protects the cooling fan age to the catalyst and other motorcycle
motor. components.
• 10A OPTION fuse protects the options.
6-82

• Do not try to start the engine by
NOTICE pushing the motorcycle or by coast-
Improper motorcycle operation can ing down a hill.
cause catalyst or other motorcycle dam- • Do not idle the engine with any
age. spark plug wires disconnected or
removed, such as during diagnos-
To avoid damage to the catalyst or other tic testing.
related components, you should take the • Do not idle the vehicle for prolonged
following precautions: periods if idling seems rough or
• Maintain the engine in the proper oper- there are other malfunctions.
ating condition. • Do not allow the fuel tank to get
• In the event of an engine malfunction, near the empty level.
particularly one involving engine mis-
fire or other apparent performance
loss, stop riding the motorcycle and
turn off the engine and have the
motorcycle serviced promptly.
• Do not shut off the engine or interrupt
the ignition when the transmission is
in gear and the motorcycle is in
motion.
6-83

 WARNING
If you park or operate the motorcycle in
areas where there are combustible mate-
rials such as dry grass or leaves, these
materials may come in contact with the
catalytic converter or other hot exhaust
components. This can cause a fire.
Avoid parking or operating your vehicle

in areas with any combustible materials.
6-84

TROUBLESHOOTING
FUEL SUPPLY CHECK .............................................................................................................................. 7-2

IGNITION SYSTEM CHECK ....................................................................................................................... 7-3
ENGINE STALLING .................................................................................................................................... 7-4
7-1

TROUBLESHOOTING FUEL SUPPLY CHECK
If the fuel injection indicator displays “FI”,
This troubleshooting guide is provided to showing signs of trouble in the fuel injection
help you find the cause of some common system, take your machine to an authorized
complaints. Suzuki dealer. Refer to the “INSTRUMENT
PANEL” section for an explanation of fuel
injection system indicator.
NOTICE
Improper repairs or adjustments may
damage the motorcycle instead of fixing
it. Such damage may not be covered
under warranty.
If you are not sure about the proper

action, consult your Suzuki dealer about
the problem.
If the engine refuses to start perform the fol-

lowing inspections to determine the cause.
7-2

IGNITION SYSTEM CHECK 2. Hold the spark plug firmly against the
1. Remove spark plugs and reattach them engine and push the starter switch with
to the spark plug caps. the ignition switch in the “ON” position,
the engine stop switch in the “” posi-
tion, the transmission in neutral, and the
clutch disengaged. If the ignition system
is operating properly, a blue spark
should jump across the spark plug gap.
If there is still no spark, take your motor-
cycle to an authorized Suzuki dealer.
7-3

ENGINE STALLING
 WARNING 1. Make sure there is enough fuel in the
fuel tank.
Performing the spark test improperly can 2. If the fuel injection indicator displays “FI”,
be hazardous. You could get a high volt- showing signs of trouble in the fuel injec-
age electrical shock if you are not famil- tion system, take your machine to an
iar with this procedure. authorized Suzuki dealer. Refer to the
“INSTRUMENT PANEL” section for an
Do not perform this check if you are not explanation of fuel injection system indi-
familiar with the procedure. Do not point cator.
the spark plug near the spark plug hole 3. Check the ignition system for intermittent
during this test. Do not perform this test spark.
if you have a heart condition or wear a 4. Check the idle speed. The correct idle
pacemaker. speed is 900 – 1100 r/min.
7-4

STORAGE PROCEDURE AND
MOTORCYCLE CLEANING
STORAGE PROCEDURE ........................................................................................................................... 8-2

PROCEDURE FOR RETURNING TO SERVICE ........................................................................................ 8-4
CORROSION PREVENTION ...................................................................................................................... 8-4
MOTORCYCLE CLEANING ....................................................................................................................... 8-6
INSPECTION AFTER CLEANING .............................................................................................................. 8-9
8-1

STORAGE PROCEDURE AND FUEL
1. Fill the fuel tank to the top with fuel
MOTORCYCLE CLEANING mixed with the amount of gasoline stabi-
lizer recommended by the stabilizer
STORAGE PROCEDURE manufacturer.
If your motorcycle is to be left unused for an 2. Run the engine for a few minutes until
extended period of time, it needs special the stabilized gasoline fills the fuel injec-
servicing requiring appropriate materials, tion system.
equipment and skill. For this reason, Suzuki
recommends that you trust this maintenance ENGINE
work to your authorized Suzuki dealer. If you 1. Remove the spark plugs. Pour one table-
wish to service the machine for storage spoon of motor oil into each spark plug
yourself, follow the general guidelines holes. Reinstall the spark plugs and
below: crank the engine a few times.
2. Drain the engine oil thoroughly and refill
MOTORCYCLE the crankcase with fresh engine oil all
Clean the entire motorcycle. Place the the way up to the filler hole.
motorcycle on the side stand on a firm, flat
surface where it will not fall over.
8-2

BATTERY MAINTENANCE DURING STORAGE
1. Remove the battery from the motorcycle Once a month, recharge the battery. The
by referring to the BATTERY section. standard charging rate is 1.8A × 5 to 10
2. Clean the outside of the battery with a hours.
mild soap and remove corrosion from the
terminals and wiring harness.
3. Store the battery in a room above freez-
ing.
TIRES
Inflate the tires to the normal specifications.
EXTERNAL
• Spray all vinyl and rubber parts with rub-
ber preservative.
• Spray the unpainted surfaces with rust
preventative.
• Coat the painted surfaces with car wax.
8-3

PROCEDURE FOR RETURNING TO CORROSION PREVENTION
SERVICE It is important to take good care of your
1. Clean the entire motorcycle. motorcycle to protect it from corrosion and
2. Reinstall the battery by referring to the keep it looking new for years to come.
BATTERY section.
3. Remove the spark plugs. Turn the IMPORTANT INFORMATION ABOUT
engine a few times by putting the trans- CORROSION
mission in top gear and turning the rear Common causes of corrosion
wheel. Reinstall the spark plugs. • Accumulation of road salt, dirt, moisture,
4. Drain the engine oil thoroughly. Replace or chemicals in hard-to-reach areas.
the oil filter with a new one and fill the • Chipping, scratches, and any damage to
engine with fresh oil as outlined in this treated or painted metal surfaces result-
manual. ing from minor accidents or impacts from
5. Adjust the pressure of tires as described stones and gravel.
in the TIRES section.
6. Lubricate all places as instructed in this Road salt, sea air, industrial pollution, and
manual. high humidity will all contribute to corrosion.
7. Do the INSPECTION BEFORE RIDING
as listed in this manual.
8-4

HOW TO HELP PREVENT CORROSION • Store your motorcycle in a dry, well-ven-
• Wash your motorcycle frequently, at tilated area. If you often wash your
least once a month. Keep your motorcy- motorcycle in the garage or if you fre-
cle as clean and dry as possible. quently park it inside when wet, your
• Remove foreign material deposits. For- garage may be damp. The high humidity
eign material such as road salt, chemi- may cause or accelerate corrosion. A
cals, road oil or tar, tree sap, bird wet motorcycle may corrode even in a
droppings and industrial fall-out may heated garage if the ventilation is poor.
damage your motorcycle’s finish. • Cover your motorcycle. Exposure to mid-
Remove these types of deposits as day sun can cause the colors in paint,
quickly as possible. If these deposits are plastic parts, and instrument faces to
difficult to wash off, an additional cleaner fade. Covering your motorcycle with a
may be required. Follow the manufac- high-quality, “breathable” motorcycle
turer’s directions when using these spe- cover can help protect the finish from the
cial cleaners. harmful UV rays in sunlight, and can
• Repair finish damage as soon as possi- reduce the amount of dust and air pollu-
ble. Carefully examine your motorcycle tion reaching the surface. Your Suzuki
for damage to the painted surfaces. dealer can help you select the right
Should you find any chips or scratches in cover for your motorcycle.
the paint, touch them up immediately to
prevent corrosion from starting. If the
chips or scratches have gone through to
the bare metal, have a Suzuki dealer
make the repair.
8-5

MOTORCYCLE CLEANING NOTE: Avoid spraying or allowing water to
WASHING THE MOTORCYCLE flow over the following places:
When washing the motorcycle, follow the • Ignition switch
instructions below: • Spark plugs
1. Remove dirt and mud from the motorcy- • Fuel tank cap
cle with cool running water. You may use • Throttle body
a soft sponge or brush. Do not use hard • Fuel injection system
materials which can scratch the paint. • Brake master cylinders
2. Wash the entire motorcycle with a mild • Air cleaner inlet
detergent or car wash soap using a • Throttle cable boots
sponge or soft cloth. The sponge or cloth
should be frequently soaked in the soap
solution.
NOTE: Clean the motorcycle immediately

after riding on road salt or riding along coast
with cool water. Be sure to use cool water
because warm water can hasten corrosion.
8-6

3. Once the dirt has been completely
NOTICE removed, rinse off the detergent with
running water.
High pressure washers such as those 4. After rinsing, wipe off the motorcycle
found at coin-operated car washes have with a wet chamois or cloth and allow it
enough pressure to damage the parts of to dry in the shade.
your motorcycle. It may cause rust, cor- 5. Check carefully for damage to painted
rosion and increase wear. Parts cleaner surfaces. If there is any damage, obtain
can also damage motorcycle parts. “touch-up” paint and “touch-up” the dam-
age following the procedure below:
Do not use high pressure washers to a. Clean all damaged spots and allow
clean your motorcycle. Do not use parts them to dry.
cleaner on throttle body and fuel injec- b. Stir the paint and “touch-up” the dam-
tion sensors. aged spots lightly with a small brush.
c. Allow the paint to dry completely.
8-7

NOTE: Headlight lens can be fogged after WAXING THE MOTORCYCLE
washing the motorcycle or riding in a rain. After washing the motorcycle, waxing and
Headlight fogging will be cleared gradually polishing are recommended to further pro-
when the headlight is turned on. To clear the tect and beautify the paint.
headlight lens fogging, run the engine to • Only use waxes and polishes of good
avoid battery discharge. quality.
• When using waxes and polishes,
observe the precautions specified by the
NOTICE manufacturers.
Cleaning your motorcycle with any alka-
line or strong acid cleaner, gasoline, WINDSHIELD CLEANING (VL1500T/BT)
brake fluid, or any other solvent will Clean the windshield with a soft cloth and
damage the motorcycle parts. warm water with a mild detergent. If
scratched, polish with a commercially avail-
Clean only with soft cloth and warm able plastic polish. Replace the windshield if
water with mild detergent. it becomes scratched or discolored so as to
obstruct view. When replacing the wind-
shield, use a Suzuki replacement wind-
shield.
8-8

SPECIAL CARE FOR MATTE FINISH INSPECTION AFTER CLEANING
PAINT For extended life of your motorcycle, lubri-
Do not use polishing compounds or waxes cate it according to the GENERAL LUBRI-
that contain polishing compounds on sur- CATION section.
faces which have a matte finish. The use of
polishing compounds will change the
appearance of the matte finish.  WARNING
Operating the motorcycle with wet
Solid type waxes may be difficult to remove
brakes can be hazardous. Wet brakes
from surfaces with a matte finish.
may not provide as much stopping
power as dry brakes. This could lead to
Friction while riding, excessive rubbing or
an accident.
polishing of a surface with a matte finish will
change its appearance.
Test your brakes after washing the
motorcycle, while riding at slow speed. If
necessary, apply the brakes several
times to let friction dry out the linings.
Follow the procedures in the INSPECTION

BEFORE RIDING section to check your
motorcycle for any problems that may have
arisen during your last ride.
8-9

SPECIFICATIONS
DIMENSIONS AND CURB MASS
Overall length ....................................................................... 2570 mm (101.2 in)
2560 mm (100.8 in) ... Canada and Australia
Overall width......................................................................... 990 mm (39.0 in)
Overall height ....................................................................... 1135 mm (44.7 in)
1440 mm (56.7 in) ... VL1500T/BT
Wheelbase ........................................................................... 1675 mm (65.9 in)
Ground clearance................................................................. 140 mm (5.5 in)
Seat height ........................................................................... 720 mm (28.3 in)
Curb mass ............................................................................ 344 kg (758 lbs)
363 kg (800 lbs) ... VL1500T/BT
ENGINE
Type...................................................................................... Four-stroke, liquid-cooled, SOHC, 54-degree, V-twin
Number of cylinders ............................................................. 2
Bore...................................................................................... 96.0 mm (3.780 in)
Stroke ................................................................................... 101.0 mm (3.976 in)
Displacement........................................................................ 1462 cm3 (89.2 cu. in)
Compression ratio ................................................................ 9.5 : 1
Fuel system .......................................................................... Fuel injection
Air cleaner ............................................................................ Paper element
Starter system ...................................................................... Electric
Lubrication system ............................................................... Wet sump

DRIVE TRAIN
Clutch ................................................................................... Wet multi-plate type
Transmission ........................................................................ 5-speed constant mesh
Gearshift pattern .................................................................. 1-down, 4-up
Primary reduction ratio ......................................................... 1.407 (76/54)
Gear ratios, Low ................................................................. 2.187 (35/16)
2nd ................................................................. 1.400 (28/20)
3rd .................................................................. 1.038 (27/26)
4rd .................................................................. 0.875 (28/32)
Top.................................................................. 0.787 (26/33)
Final reduction ratio.............................................................. 3.137 (20/17 × 32/12)
Drive system......................................................................... Shaft drive
CHASSIS
Front suspension .................................................................. Telescopic, coil spring, oil damped
Rear suspension .................................................................. Link type, coil spring, oil damped
Front fork stroke ................................................................... 130 mm (5.1 in)
Rear wheel travel.................................................................. 108 mm (4.3 in)
Caster................................................................................... 31° 10’
Trail....................................................................................... 132 mm (5.2 in)
Steering angle ...................................................................... 37° (right & left)
Turning radius....................................................................... 3.3 m (10.8 ft)
Front brake ........................................................................... Disk brake
Rear brake............................................................................ Disk brake
Front tire size........................................................................ 130/80R17M/C 65H, tubeless
Rear tire size ........................................................................ 200/60R16M/C 79H, tubeless

ELECTRICAL
Ignition type .......................................................................... Electronic ignition (Transistorized)
Spark plug ............................................................................ NGK CPR6EA-9 or DENSO U20EPR9
Battery.................................................................................. 12V 64.8kC (18Ah)/10HR
Generator ............................................................................. Three-phase A.C. Generator
Main fuse.............................................................................. 30A
Fuse ..................................................................................... 10/10/15/10/10/15/10A
Headlight .............................................................................. 12V 60/55W (H4)
Position light (if equipped) .................................................... 12V 5W
Brake light/Taillight................................................................ LED
Front turn signal light............................................................ 12V 21W
Rear turn signal light ............................................................ 12V 21W
License plate light................................................................. 12V 5W
Speedometer light ................................................................ LED
High beam indicator light...................................................... LED
Neutral indicator light............................................................ LED
Turn signal indicator light...................................................... LED
Coolant temperature indicator light ...................................... LED
Oil pressure indicator light.................................................... LED
Fuel injection indicator light .................................................. LED

CAPACITIES
Fuel tank............................................................................... 18.0 L (4.8/4.0 US/lmp. gal)
Engine oil, without filter change .......................................... 3000 ml (3.2/2.6 US/lmp. qt)
With filter change .............................................. 3200 ml (3.4/2.8 US/lmp. qt)
Final gear oil......................................................................... 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/lmp. oz)
Engine coolant...................................................................... 2.7 L (2.9/2.4 US/Imp. qt)

INDEX
A E
ACCESSORY USE AND MOTORCYCLE ENGINE COOLANT SOLUTION ................ 3-8
LOADING....................................................1-2 ENGINE IDLE SPEED INSPECTION....... 6-40
AIR CLEANER..........................................6-17 ENGINE OIL ...................................... 3-5,6-30
ALLOW THE ENGINE OIL TO CIRCULATE ENGINE STALLING ................................... 7-4
BEFORE RIDING .......................................4-4
AVOID CONSTANT LOW SPEED .............4-3 F
FINAL GEAR OIL .............................. 3-7,6-47
B FRONT WHEEL REMOVAL..................... 6-64
BATTERY .................................................6-11 FUEL HOSE ............................................. 6-40
BRAKES ...................................................6-49 FUEL OCTANE RATING............................ 3-2
BREAKING IN THE NEW TIRE..................4-3 FUEL SUPPLY CHECK.............................. 7-2
FUEL TANK CAP ..................................... 2-26
C FUSES...................................................... 6-80
CARRYING A PASSENGER ....................5-12
CATALYTIC CONVERTER ......................6-82 G
CLUTCH ADJUSTMENT ..........................6-42 GEARSHIFT LEVER ................................ 2-28
COOLANT ................................................6-44
CORROSION PREVENTION .....................8-4

H L
HELMET HOLDER ...................................2-30 LABELS ...................................................... 1-8
LEFT HANDLEBAR.................................. 2-19
I LIGHT BULB REPLACEMENT................. 6-72
IGNITION SWITCH.....................................2-5 LOCATION OF PARTS .............................. 2-2
IGNITION SYSTEM CHECK ......................7-3 LUBRICATION POINTS ........................... 6-10
INSPECTION AFTER CLEANING..............8-9
INSPECTION BEFORE RIDING ................4-5 M
INSTRUMENT PANEL ...............................2-8 MAINTENANCE SCHEDULE..................... 6-2
MAXIMUM THROTTLE OPENING
K RECOMMENDATION................................. 4-2
KEY.............................................................2-5 MOTORCYCLE CLEANING....................... 8-6

N P
NOISE CONTROL SYSTEM PROCEDURE FOR RETURNING TO
(AUSTRALIA ONLY).................................1-10 SERVICE.................................................... 8-4
O R
OBSERVE YOUR FIRST AND REAR BRAKE PEDAL.............................. 2-29
MOST CRITICAL SERVICE .......................4-4 REAR WHEEL REMOVAL ....................... 6-67
OXYGENATED FUEL RIDING ON HILLS...................................... 5-8
RECOMMENDATION.................................3-3 RIGHT HANDLEBAR ............................... 2-22

S T
SAFE RIDING RECOMMENDATION FOR THROTTLE CABLE ADJUSTMENT......... 6-38
MOTORCYCLE RIDERS............................1-6 TIRES ....................................................... 6-57
SERIAL NUMBER LOCATION ...................1-8 TOOLS ....................................................... 6-9
SIDE STAND ............................................2-31
SIDE STAND/IGNITION INTERLOCK U
SYSTEM ...................................................6-63 USING THE TRANSMISSION.................... 5-6
SIDECASE (VL1500T/BT) ........................2-32
SPARK PLUGS ........................................6-25 V
STARTING OFF .........................................5-4 VARY THE ENGINE SPEED...................... 4-2
STARTING THE ENGINE...........................5-2
STEERING LOCK.......................................2-7
STOPPING AND PARKING .......................5-8
STORAGE PROCEDURE ..........................8-2
Total page: 188

T
4th cover
Part No. 99011-06J52-01A December, 2014 EN

© COPYRIGHT SUZUKI MOTOR CORPORATION 2014
TK C L5
Printed in Japan
VL1500B/T/BT (99011-06J52-01A) 8

Manual Propietario Intruder - vl1500b

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Propietario Intruder - vl1500b

Uploaded by

Copyright:

Available Formats

p

This manual should be considered a permanent part of the

Downloaded from www.Manualslib.com manuals search engine

Motorcycle reliability and performance

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

G.V.W.: 560 kg (1230 lbs)

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Please write down the numbers in the box

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

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

Downloaded from www.Manualslib.com manuals search engine

1 Clutch lever 5 Right handlebar switches

Downloaded from www.Manualslib.com manuals search engine

9 Air cleaner G Engine oil filter

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

NOTE: Start the engine promptly after turn-

If the motorcycle falls down, turn the

Downloaded from www.Manualslib.com manuals search engine

Never attempt to move the motorcycle

Turn the handlebars all the way to the left.

Downloaded from www.Manualslib.com manuals search engine

If the speedometer needle does not point to

2. Hold the button 9 for 3 seconds.

NOTE: Reset procedure, from step 1 to step

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

If the engine coolant temperature indica-

Downloaded from www.Manualslib.com manuals search engine

B. The display 7 in the odometer display

The engine may continue to run in mode A,

Downloaded from www.Manualslib.com manuals search engine

engine will not start.

Downloaded from www.Manualslib.com manuals search engine

If the display still indicates “CHEC” after

Downloaded from www.Manualslib.com manuals search engine

To change the display, push the button 8.

Instrument panel light brightness

Downloaded from www.Manualslib.com manuals search engine

3. Push the button 8 to highlight the

Downloaded from www.Manualslib.com manuals search engine

NOTE: The odometer display locks at

Downloaded from www.Manualslib.com manuals search engine

NOTE: The trip meter will be reset to zero

Downloaded from www.Manualslib.com manuals search engine

NOTE: The fuel meter will not indicate cor-

rectly when the motorcycle is placed on the

Downloaded from www.Manualslib.com manuals search engine

HEADLIGHT FLASHER SWITCH 2

Downloaded from www.Manualslib.com manuals search engine

Use the dimmer switch to select only the