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99011-48G59-01A

VZ

R1800/B

Z

Part No. 99011-48G59-01A September, 2014 EN© COPYRIGHT SUZUKI MOTOR CORPORATION 2014 Printed in Japan

VZR1800/BZOWNER’S MANUAL

TK L5

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Pantone 303C (CMYK: 100, 0, 0, 85)Pantone 485 (CMYK: 0, 100, 100, 0 )Pantone 294 (CMYK: 100, 70, 0, 0)Black

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4 mmVZR1800/BZ (99011-48G59-01A) 4 mmVZR1800/BZ (99011-48G59-01A) 4 mmVZR1800/BZ (99011-48G59-01A) 4 mmVZR1800/BZ (99011-48G59-01A)

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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.

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Black4/14 mmVZR1800/BZ (99011-48G59-01A)



IMPORTANT

BREAK-IN (RUNNING-IN) INFORMATION FOR YOUR MOTORCYCLEThe first 1600 km (1000 miles) are themost important in the life of yourmotorcycle. Proper break-in operationduring this time will help ensure maxi-mum life and performance from yournew motorcycle. Suzuki parts aremanufactured of high quality materi-als and machined parts are finishedto close tolerances. Proper break-inoperation allows the machined sur-faces to polish each other and matesmoothly.

Motorcycle reliability and perfor-mance depend on special care andrestraint exercised during the break-inperiod. It is especially important thatyou avoid operating the engine in amanner which could expose theengine parts to excessive heat.

Please refer to the BREAK-IN (RUN-NING-IN) section for specific break-inrecommendations.

WARNING/CAUTION/NOTICE/NOTEPlease read this manual and follow itsinstructions carefully. To emphasizespecial information, the symbol and the words WARNING, CAUTION,NOTICE and NOTE have specialmeanings. Pay particular attention tomessages highlighted by these sig-nal words:

NOTE: Indicates special informationto make maintenance easier orinstructions clearer.

WARNINGIndicates a potential hazard thatcould result in death or seriousinjury.

CAUTIONIndicates a potential hazard thatcould result in minor or moderateinjury.

NOTICEIndicates a potential hazard thatcould result in vehicle or equip-ment damage.



FOREWORD

Motorcycling is one of the most exhil-arating sports and to ensure yourriding enjoyment, you should becomethoroughly familiar with the informa-tion presented in this Owner’s Manualbefore riding the motorcycle.

The proper care and maintenancethat your motorcycle requires is out-lined in this manual. By followingthese instructions explicitly you willensure a long trouble-free operatinglife for your motorcycle. Your autho-rized Suzuki dealer has experiencedtechnicians that are trained to provideyour machine with the best possibleservice with the right tools and equip-ment.

All information, illustrations and speci-fications contained in this manual arebased on the latest product informa-tion available at the time of publica-tion. Due to improvements or otherchanges, there may be some discrep-ancies between information in thismanual and your motorcycle. Suzukireserves the right to make changes atany time.

Please note that this manual appliesto all specifications for all respectivedestinations and explains all equip-ments. Therefore, your model mayhave different standard features fromthose shown in this manual.



TABLE OF CONTENTS

1

2

3

4

5

6

7

8

CONSUMER INFORMATION

CONTROLS

FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS

BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING

RIDING TIPS

INSPECTION AND MAINTENANCE

TROUBLESHOOTING

STORAGE PROCEDURE AND MOTORCYCLE CLEANING

SPECIFICATIONS

INDEX



1-1

1


ACCESSORY USE AND MOTORCYCLE LOADING ......................................... 1-2MODIFICATION ................................................................................................... 1-4SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ................ 1-4LABELS ............................................................................................................... 1-5SERIAL NUMBER LOCATION ............................................................................ 1-6NOISE CONTROL SYSTEM (AUSTRALIA ONLY) ............................................ 1-6



1-2


ACCESSORY USE AND MOTORCYCLE LOADING

Accessory UseThe addition of unsuitable accesso-ries can lead to unsafe operating con-ditions. It is not possible for Suzuki totest each accessory on the market orcombinations of all the availableaccessories; however, your dealercan assist you in selecting qualityaccessories and installing them cor-rectly. Use extreme caution whenselecting and installing the accesso-ries on your motorcycle and consultyour Suzuki dealer if you have anyquestions.

Accessory installation guideline• Install aerodynamic-affecting

accessories, such as a fairing,windshield, backrests, saddle-bags, and travel trunks, as low aspossible, as close to the motorcy-cle and as near to the center ofgravity as is feasible. Check thatthe mounting brackets and otherattachment hardware are rigidlymounted.

• Inspect for proper ground clear-ance and bank angle. Inspect thatthe accessory does not interferewith the operation of the suspen-sion, steering or other controloperations.

• Accessories fitted to the handle-bars or the front fork area can cre-ate serious stability problems.This extra weight will cause themotorcycle to be less responsiveto your steering control. Theweight may also cause oscillationsin the front end and lead to insta-bility problems. Accessoriesadded to the handlebars or frontfork of the machine should be aslight as possible and kept to aminimum.

• Certain accessories displace therider from his or her normal ridingposition. This limits the freedom ofmovement of the rider and maylimit his or her control ability.

• Additional electrical accessoriesmay overload the existing electri-cal system. Severe overloads maydamage the wiring harness or cre-ate a dangerous situation due tothe loss of electrical power duringthe operation of the motorcycle.

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

WARNINGImproper installation of accesso-ries or modification of the motor-cycle may cause changes inhandling which could lead to anaccident.

Never use improper accessories,and make sure that any accesso-ries that are used are properlyinstalled. All parts and accesso-ries added to the motorcycleshould be genuine Suzuki parts ortheir equivalent designed for useon this motorcycle. Install and usethem according to their instruc-tions. If you have any questions,contact your Suzuki dealer.



1-3

Loading Limit

• Never exceed the G.V.W. (GrossVehicle Weight) of this motorcycle.The G.V.W. is the combinedweight of the machine, accesso-ries, payload, rider and passen-ger. When selecting youraccessories, keep in mind theweight of the rider as well as theweight of the accessories. Theadditional weight of the accesso-ries may not only create an unsaferiding condition but may alsoaffect the riding stability.

G.V.W.: 565 kg (1250 lbs)at the tire pressure (cold)Front: 250 kPa (2.50 kgf/cm2, 36 psi)Rear: 290 kPa (2.90 kgf/cm2, 42 psi)

Loading GuidelinesThis motorcycle is primarily intendedto carry small items when you are notriding with a passenger. Follow theguidelines below to carry a passengeror cargo:• Balance the load between the left

and right side of the motorcycleand fasten it securely.

• Place cargo weight as close to thecenter of the motorcycle as possi-ble.

• Do not attach large or heavy itemsto the handlebars, front forks orrear fender.

• Check that both tires are properlyinflated to the specified tire pres-sure for your loading conditions.Refer to page 6-36.

• Improperly loading your motorcy-cle can reduce your ability to bal-ance and steer the motorcycle.You should ride at reducedspeeds, less than 130 km/h (80mph), when you are carryingcargo or have added accessories.

• Adjust suspension settings asnecessary.

WARNINGOverloading or improper loadingcan cause loss of motorcycle con-trol and an accident.

Follow loading limits and loadingguidelines in this manual.



1-4

MODIFICATIONModification of the motorcycle, orremoval of original equipment mayrender the vehicle unsafe or illegal.

SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERSMotorcycle riding is great fun and anexciting sport. Motorcycle riding alsorequires that some extra precautionsbe taken to ensure the safety of therider and passenger. These precau-tions are:

WEAR A HELMETMotorcycle safety equipment startswith a quality helmet. One of the mostserious injuries that can happen is ahead injury. ALWAYS wear a properlyapproved helmet. You should alsowear suitable eye protection.

RIDING APPARELLoose, fancy clothing can be uncom-fortable and unsafe when riding yourmotorcycle. Choose good qualitymotorcycle riding apparel when ridingyour motorcycle.

INSPECTION BEFORE RIDINGReview thoroughly the instructions inthe INSPECTION BEFORE RIDINGsection of this manual. Do not forgetto perform an entire safety inspectionto ensure the safety of the rider andits passenger.

FAMILIARIZE YOURSELF WITH THE MOTORCYCLEYour riding skill and your mechanicalknowledge form the foundation forsafe riding practices. We suggest thatyou practice riding your motorcycle ina non-traffic situation until you arethoroughly familiar with your machineand its controls. Remember practicemakes perfect.

KNOW YOUR LIMITSRide within the boundaries of yourown skill at all times. Knowing theselimits and staying within them will helpyou to avoid accidents.

BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYSRiding on bad weather days, espe-cially wet ones requires extra caution.Braking distances double on a rainyday. Stay off of the painted surfacemarks, manhole covers and greasyappearing areas as they can be espe-cially slippery. Use extreme caution atrailway crossings and on metal grat-ings and bridges. When-ever in doubtabout road condition, slow down!



1-5

RIDE DEFENSIVELYThe most common type of motorcycleaccident occurs when a car travelingtowards a motorcycle turns round cor-ner in front of the motorcyclist. Ridedefensively. Wise motorcyclist uses astrategy of assuming they are invisibleto other drivers, even in broad day-light. Wear bright, reflecting clothing.Turn on the headlight and taillightevery time even on a bright, sunnyday to attract driver’s attention. Do notride in another driver’s blind spot.

LABELSRead and follow all the labels on themotorcycle. Make sure you under-stand all of the labels. Do not removeany labels from the motorcycle.



1-6

SERIAL NUMBER LOCATIONThe frame and/or engine serial num-bers are used to register the motorcy-cle. They are also used to assist yourauthorized Suzuki dealer when order-ing parts or referring to special ser-vice information.

The frame number 1 is stamped onthe steering head. The engine serialnumber 2 is stamped on the crank-case assembly.

Please write down the numbers in thebox provided below for your future ref-erence.

NOISE CONTROL SYSTEM (AUSTRALIA ONLY)

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITEDOwners are warned that the law mayprohibit:(a) The removal or rendering inopera-

tive by any person other than forpurposes of maintenance, repairor replacement, of any device orelement of design incorporatedinto any new vehicle for the pur-pose of noise control prior its saleor delivery to the ultimate pur-chaser or while it is in use; and

(b) The use of the vehicle after suchdevice or element of design hasbeen removed or rendered inoper-ative by any person.

Frame number:

Engine number:



2-1

2CONTROLS

LOCATION OF PARTS ....................................................................................... 2-2KEY ...................................................................................................................... 2-5IGNITION SWITCH .............................................................................................. 2-5STEERING LOCK ................................................................................................ 2-6INSTRUMENT PANEL ......................................................................................... 2-7LEFT HANDLEBAR ........................................................................................... 2-13RIGHT HANDLEBAR ........................................................................................ 2-16FUEL TANK CAP .............................................................................................. 2-18GEARSHIFT LEVER .......................................................................................... 2-19REAR BRAKE PEDAL ...................................................................................... 2-19SEAT LOCK ....................................................................................................... 2-20HELMET HOLDER ............................................................................................ 2-21SIDE STAND ...................................................................................................... 2-21SUSPENSION ADJUSTMENT .......................................................................... 2-22SEAT TAIL COVER ........................................................................................... 2-24



2-2

CONTROLS

LOCATION OF PARTS

1 Clutch lever2 Left handlebar switches3 Instrument panel4 Front brake fluid reservoir5 Right handlebar switches6 Throttle grip7 Front brake lever8 Fuel tank cap

Canada, Australia, Middle East



2-3

9 Air cleaner0 Spark plugA Ignition switchB Battery and toolsC Main fuse and fusesD Seat lockE Helmet holderF Engine coolant reservoirG Gearshift leverH FootrestsI Engine oil filler capJ Speed sensorK Side standL Passenger footrests



2-4

M Engine oil drain plugN Rear brake pedalO Engine oil filterP Rear brake light switch



2-5

KEY

This motorcycle comes equipped witha main ignition key and a spare one.Keep the spare key in a safe place.

IGNITION SWITCH

The ignition switch has 3 positions:

“OFF” POSITIONAll electrical circuits are cut off. Theengine will not start. The key can beremoved.

“ON” POSITIONThe ignition circuit is completed andthe engine can now be started. Theheadlight, front turn signal light (Can-ada, Middle East) and taillight willautomatically be turned on when thekey is in this position. The key cannotbe removed from the ignition switch inthis position.

NOTE: Start the engine promptly afterturning the key to the “ON” position,or the battery will lose power due toconsumption by the headlight and tail-light.

“P” (Parking) POSITIONWhen parking the motorcycle, lockthe steering and turn the key to the“P” position. The key can now beremoved and the *position light andtaillight will remain lit. This position isfor night time roadside parking toincrease visibility.

* Canadian and Middle East modeldoes not have position light.



2-6

STEERING LOCK

Turn the handlebars all the way to theleft. Insert the ignition key into thesteering lock and turn it counterclock-wise to lock the steering.

WARNINGIf the motorcycle falls down due toa slip or collision, unexpecteddamage to the motorcycle couldcause the engine to keep running,which could result in a fire, orcould result in injury from movingparts such as the rear wheel.

If the motorcycle falls down, turnthe ignition switch off immedi-ately. Ask your authorized Suzukidealer to inspect the motorcyclefor unseen damage.

WARNINGMoving the motorcycle while thesteering is locked can be hazard-ous. You could lose your balanceand fall, or you could drop themotorcycle.

Never attempt to move the motor-cycle when the steering is locked.



2-7

INSTRUMENT PANEL

The fuel injection system indicatorlight 7, fuel indicator light 8, oil pres-sure indicator light/coolant tempera-ture indicator light 9, LCD’s andspeedometer needle work as followsto confirm their function when theignition switch is turned to the “ON”position.

• The fuel injection system indicatorlight 7, fuel indicator light 8 andoil pressure indicator light/coolanttemperature indicator light 9come on for 3 seconds.

• The speedometer needle movesto the full scale position andreturns to the home position.

• All LCD segments will haveappear action and then show nor-mal display.

TACHOMETER 1The tachometer indicates the enginespeed in revolutions per minute (r/min).

GEAR POSITION INDICATOR 2The gear position indicator indicatesgear position. This indicator displays“0” when the transmission is in neu-tral.

NOTE: When the display indicates“CHEC”, the gear position indicatordoes not indicate a number but indi-cates “–”.

TURN SIGNAL INDICATOR LIGHT “” 4When the turn signals are being oper-ated either to the right or to the left,the indicator light will blink intermit-tently.

NOTE: If a turn signal light is notoperating properly due to bulb fila-ment or circuit failure, the indicatorlight blinks more quickly to notify therider of the existence of a problem.

HIGH BEAM INDICATOR LIGHT “” 5The blue indicator light will come onwhen the headlight high beam isturned on.

NEUTRAL INDICATOR LIGHT “N” 6The green light will come on when thetransmission is in neutral. The lightwill go out when you shift into anygear other than neutral.



2-8

FUEL INJECTION SYSTEM INDICATOR “FI” 7

If the fuel injection system fails, thered indicator light 7 comes on andthe display D indicates “FI” in the fol-lowing two modes;

A. The display D indicates “FI” andmileage alternately, and the redindicator light 7 comes on andremains lit.

B. The display D indicates “FI” con-tinuously and the red indicatorlight 7 blinks while cranking theengine.

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

NOTE: • If the display D indicates “FI” and

mileage alternately and the redindicator light comes on andremains lit, keep the engine run-ning and bring your motorcycle toan authorized Suzuki dealer. If theengine stalls, try restarting theengine after turning the ignitionswitch off and on.

• If the display D indicates “FI” con-tinuously and the red indicator lightblinks, the engine will not start.

NOTICEThe fuel injection indicator comeson to indicate a problem with thefuel injection system. Riding themotorcycle with the fuel injectionindicator lit can damage theengine and transmission.

If the display indicates “FI” andthe red indicator light comes on,have your authorized Suzukidealer or a qualified mechanicinspect the fuel injection systemas soon as possible.



2-9

When the display D indicates“CHEC”, check following items;• Make sure that the engine stop

switch is in the “” position.• Make sure that the transmission is

in neutral or the side stand is fullyup.

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

OIL PRESSURE INDICATOR LIGHT/COOLANT TEMPERATURE INDICATOR LIGHT “ ” 9This indicator light comes on in thedisplay when the engine oil pressureis below the normal operating range,coolant temperature is too high. Thisindicator should come on when theengine is not running. As soon as theengine starts, this indicator should goout.

Oil PressureWith the ignition switch in the “ON”position but the engine is not started,the symbol “” 3 in the displayand the indicator light 9 comes on.

Coolant TemperatureWhen the coolant temperature ishigher than 120°C, the symbol “”3 and indicator light 9 come on.When the coolant temperature indica-tor light comes on, stop the engineand check the coolant level afterengine cools.

NOTICERiding the motorcycle with the oilpressure indicator light lit candamage the engine and transmis-sion.

If the oil pressure indicator lightcomes on, indicating low oil pres-sure, stop the engine immediately.Check the oil level and add oil ifnecessary. If there is a properamount of oil and the light stilldoes not go out, have your autho-rized Suzuki dealer or a qualifiedmechanic inspect your motorcy-cle.

NOTICERiding the motorcycle with thecoolant temperature indicator litcan cause serious engine damagedue to overheating.

If the engine coolant temperatureindicator light comes on, stop theengine to let it cool. Do not run theengine until the coolant tempera-ture indicator light goes off.



2-10

SPEEDOMETER 0The speedometer indicates the roadspeed in miles per hour and/or kilo-meters per hour.

If the speedometer needle does notpoint to zero, follow the procedurebelow to reset the speedometer.

1. Press and hold the ADJ button Cand turn on the ignition switch.

2. Hold the ADJ button C for 3 – 5seconds.

3. Release the ADJ button C. Rapthe ADJ button twice.

NOTE: Reset procedure, from step 1to step 3, should be performed within10 seconds.

CLOCK/FUEL METER AThe display in the speedometer hastwo functions, clock and fuel meter.

Clock The clock has a 12-hour display. Fol-low the procedure below to adjust theclock.

1. Push the buttons, SEL B andADJ C, simultaneously for 2 sec-onds until the hour display blinks.

2. Adjust the hour display by pushingthe ADJ button C.

NOTE: When the ADJ button C isheld in the display advances continu-ously.

3. Push the SEL button B to high-light the minute display.

4. Adjust the minute display by push-ing the ADJ button C.

5. Push the SEL button B to returnto the clock mode.

E F



2-11

Fuel meter “”The fuel meter indicates the amountof fuel remaining in the fuel tank. Thefuel meter displays all 5 segmentswhen the fuel tank is full. The markblinks when the fuel level drops below4.0 L (4.2/3.5 US/Imp. qt). The markand segment blink when the fueldrops below 1.5 L (1.6/1.3 US/Imp.qt).

NOTE: The fuel meter indicates cor-rectly when the motorcycle is heldupright.

Fuel indicator light “”When the fuel in the fuel tank dropsbelow approximately 4.0 L (4.2/3.5US/lmp. qt), this INDICATOR “” 8blinks. When the fuel in the fuel tankdrops below approximately 1.5 L (1.6/1.3 US/lmp. qt), this indicator lightcomes on. This indicator light comeson for a few seconds when the igni-tion switch is turned to the “ON” posi-tion, then the indicator light should goout if there is enough fuel in the tank.

NOTE: When the fuel indicator lightcomes on, you should add fuel to thefuel tank at the first opportunity toavoid running out of fuel.

WARNINGChanging the display while ridingcan be hazardous. Removing ahand from the handlebars canreduce your ability to control themotorcycle.

Never change the display whileriding. Keep both hands on thehandlebars.

Fuel tank

Fuel gauge

Approximately1.5 L

Full

Blink

Approximately4.0 L

Indicator Blink

Mark Blink Blink



2-12

ODOMETER/TRIP METER DThis display has three functions;odometer and two trip meters. Whenthe ignition switch is turned to the“ON” position, the test pattern shownbelow is displayed for three seconds.Then the display changes to odome-ter or trip meter, according to whatwas selected before turning the igni-tion switch off.

To change the display, push the SELbutton B. The display changes in theorder below.

OdometerThe odometer registers the total dis-tance that the motorcycle has beenridden. The odometer ranges from 0to 999999.

NOTE: The odometer display locks at999999 when the total distanceexceeds 999999.

ODO TRIP 12

ODO

TRIP1

TRIP 2

Odometer

Trip meter 1

Trip meter 2



2-13

Trip metersThe two trip meters are resettableodometers. They can register twokinds of distances at the same time.For instance, trip meter 1 can registerthe trip distance and trip meter 2 canregister the distance between fuelstops.

To reset a trip meter to zero, push theADJ button C for two seconds whilethe display indicates the trip meter 1,or 2, you want to reset.

NOTE: When the trip meter exceeds9999.9, the trip meter will return to 0.0and start counting again.

NOTE: The trip meter will be reset tozero when the battery is removed orbattery is discharged.

LEFT HANDLEBAR

CLUTCH LEVER 1The clutch lever is used for disengag-ing the drive to the rear wheel whenstarting the engine or shifting trans-mission gears. Squeezing the leverdisengages the clutch.

HEADLIGHT FLASHER SWITCH 2 Press the switch to flash the head-light.

WARNINGChanging the display while ridingcan be hazardous. Removing ahand from the handlebars canreduce your ability to control themotorcycle.

Never change the display whileriding. Keep both hands on thehandlebars.



2-14

DIMMER SWITCH 3“” positionThe headlight low beam and taillightturn on.

“” positionThe headlight high beam and taillightturn on. The high beam indicator lightalso turns on.

NOTICEHolding the dimmer switchbetween the “” and “” posi-tion will light both the high andlow headlight beam. This improperoperation can damage the motor-cycle’s headlight.

Use the dimmer switch to selectonly the “” or “” position.

NOTICESticking tape or placing objects infront of the headlight can obstructheadlight heat radiation. This canresult in headlight damage.

Do not stick tape on the headlightor place objects in front of theheadlight.

NOTICEDo not put objects in front of theheadlight or taillight turned on,and do not cover with clotheswhen the motorcycle is stopped.

This may cause melting of thelens or damaging of the set objectby the heat of lens.



2-15

TURN SIGNAL LIGHT SWITCH “” 4Moving the switch to the “” positionwill flash the left turn signal. Movingthe switch to the “” position willflash the right turn signal. The indica-tor light will also flash intermittently.To cancel turn signal operation, pushthe switch on.

HORN SWITCH “” 5Press the switch to sound the horn.

HAZARD WARNING SWITCH “” 6 All four turn signal lights and indica-tors will flash simultaneously whenthe switch is turned on with the igni-tion switch in the “ON” or “P” position.Use the hazard warning lights to warnother traffic during emergency park-ing or when your vehicle could other-wise become a traffic hazard.

WARNINGFailure to use the turn signals,and failure to turn off the turn sig-nals can be hazardous. Other driv-ers may misjudge your course andthis may result in an accident.

Always use the turn signals whenyou intend to change lanes ormake a turn. Be sure to turn offthe turn signals after completingthe turn or lane change.



2-16

RIGHT HANDLEBAR

ENGINE STOP SWITCH 1“” positionThe ignition circuit is off. The enginecannot start or run.

“” positionThe ignition circuit is on and theengine can run.

FRONT BRAKE LEVER 2The front brake is applied by squeez-ing the brake lever gently toward thethrottle grip. This motorcycle isequipped with disk brake system andexcessive pressure is not required toslow the machine down properly. Thebrake light will come on when thelever is squeezed inward.

Front brake lever adjustment

The distance between the throttle gripand the front brake lever is adjustableto 5 positions. To change the position,push the brake lever forward and turnthe adjuster to the desired position.When changing the brake lever posi-tion, always be sure the adjusterstops in the proper position; a projec-tion of the brake lever holder should fitinto the depression of the adjuster.This motorcycle is delivered from thefactory with its adjuster set to position3.

WARNINGAdjusting the front brake leverposition while riding can be haz-ardous. Removing a hand from thehandlebars can reduce your abilityto control the motorcycle.

Never adjust the front brake leverposition while riding. Keep bothhands on the handlebars.



2-17

ELECTRIC STARTER SWITCH “” 3This switch is used for operating thestarter motor. With the ignition switchin the “ON” position, the engine stopswitch in “”, the clutch disengaged,push the electric starter switch tooperate the starter motor and startthe engine.

NOTE: This motorcycle is equippedwith interlock system for the ignitioncircuit and the starter circuit. Theengine 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 theclutch is disengaged.

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

THROTTLE GRIP 4Engine speed is controlled by theposition of the throttle grip. Turn ittoward you to increase engine speed.Turn it away from you to decreaseengine speed.

NOTICEEngaging the starter motor formore than five seconds at a timecan damage the starter motor andwiring harness from overheating.

Do not engage the starter motorfor more than five seconds at atime. If the engine does not startafter several attempts, check thefuel supply and ignition system.Refer to the TROUBLESHOOTINGsection in this manual.



2-18

FUEL TANK CAP

To open the fuel tank cap, insert theignition key into the lock and turn itclockwise. With the key inserted, liftthe cap up with key. To close the fueltank cap, push the cap down firmlywith the key in the cap lock.

Use fresh gasoline when filling up thefuel tank. Do not use bad gasolinewhich is contaminated with dirt, dust,water or other liquid. Be careful thatdirt, dust or water does not enter thefuel tank when refueling.

Face the arrow mark forward whenrefitting the fuel tank cap.

1 Fuel level2 Filler neck

WARNINGIf you overfill the fuel tank, fuelmay overflow when it expands dueto engine heat or heating by thesun. Fuel that overflows can catchfire.

Stop adding fuel when the fuellevel reaches the bottom of thefiller neck.

WARNINGFailure to follow safety precau-tions when refueling could resultin a fire or cause you to breathetoxic fumes.

Refuel in a well ventilated area.Make sure the engine is off andavoid spilling fuel on a hot engine.Do not smoke, and make surethere are no open flames orsparks in the area. Avoid breath-ing gasoline vapors. Keep chil-dren and pets away when yourefuel the motorcycle.



2-19

GEARSHIFT LEVER

This motorcycle has a 5-speed trans-mission which operates as shown. Toshift properly, squeeze the clutchlever and close the throttle at thesame time you operate the gearshiftlever. Lift the front end of the gearshift lever to upshift. Depress the frontend of the gearshift lever to downshift.Neutral is located between 1st and2nd gear. When neutral is desired,depress or lift the lever halfwaybetween 1st and 2nd gear.

NOTE: When the transmission is inneutral, the green indicator light onthe instrument panel will be lit. How-ever, even though the light is illumi-nated, cautiously and slowly releasethe clutch lever to make sure that thetransmission is positively in neutral.

Reduce your road speed beforedown-shifting. When down-shifting,the engine speed should beincreased before the clutch isengaged. This will prevent unneces-sary wear on the drive train compo-nents and rear tire.

REAR BRAKE PEDAL

Depressing the rear brake pedal willapply the rear brake. The brake lightwill come on when the rear brake isoperated.



2-20

SEAT LOCK

1. The seat lock is located under theleft frame cover. To remove theseat, insert the ignition key intothe lock and turn it clockwise.

2. Raise the rear end of the seat andslide it backward.

To reinstall the seat, slide the seathook into the seat hook retainer andpush down firmly until the seat snapsinto the locked position.

WARNINGFailure to install the seat properlycould allow the seat to move andcause loss of rider control.

Latch the seat securely in itsproper position.



2-21

HELMET HOLDER

The helmet holder is located on theleft side below the rear seat. Insertthe key and turn it clockwise to openthe latch. Hook your helmet fastenerring to the latch and turn the key backto lock the holder.

SIDE STAND

This motorcycle is equipped with aside stand to support the motorcyclewhen parking. An interlock system isprovided to cut off the ignition circuitwhen the side stand is down and thetransmission is in any gear other thanneutral.

The side stand/ignition interlock sys-tem works as follows:• If the side stand is down and the

transmission is in gear, the enginecan not be started.

• If the engine is running and thetransmission is shifted into gearwith the side stand down, theengine will stop running.

• If the engine is running and theside stand is put down with thetransmission in gear, the enginewill stop running.

WARNINGRiding with a helmet fastened tothe helmet holder can interferewith rider control.

Never carry a helmet fastened tothe helmet holder. Fix the helmetsecurely atop the seat if you mustcarry it.



2-22

SUSPENSION ADJUSTMENTREAR SUSPENSION Spring Pre-load AdjustmentThe rear suspension spring pre-loadis adjustable to compensate for therider, load, riding style and road con-ditions. The spring pre-load is adjust-able to seven positions. To changethe spring pre-load setting, follow theprocedure below.

1. Place the motorcycle on the sidestand.

WARNINGRiding with the side stand incom-pletely retracted can result in anaccident when you turn left.

Check operation of the side stand/ignition interlock system beforeriding. Always retract the sidestand completely before startingoff.

NOTICEIf you do not take proper precau-tions when parking, the motorcy-cle can fall over.

Park the motorcycle on firm, levelground whenever possible. If youmust park on an incline, aim thefront of the motorcycle uphill andput the transmission into 1st gearto reduce the possibility of rollingoff the side stand.



2-23

2. Twist the spring tension ring to thedesired position with an adjuster.Position 1 provides the softestspring tension and position 7 pro-vides the stiffest. This motorcyclesis delivered from the factory withits adjuster set on position 4.

NOTE: Use a hook type springadjuster or Suzuki spring adjuster,Part number 09822-00003 to adjustthe rear suspension spring. TheSuzuki spring adjuster is availablefrom your Suzuki dealer.

Rear Suspension Label

NOTE: Ask your Suzuki dealer to dis-pose of the rear suspension unit.

WARNING

This unit contains high-pressurenitrogen gas.Mishandling can cause explosion.

• Keep away from fire and heat.• Read owner’s manual for more

information.



2-24

SEAT TAIL COVERA seat tail cover for solo riding can beattached to the motorcycle. Toreplace the rear seat with the seat tailcover, follow the procedure below.

1. Remove the front seat by referringto the SEAT LOCK section.

2. Remove the bolts 1.

3. Replace the rear seat with theseat tail cover.

4. Tighten the bolts 2 securely.



3-1

3


FUEL OCTANE RATING ..................................................................................... 3-2OXYGENATED FUEL RECOMMENDATION ...................................................... 3-2ENGINE OIL ......................................................................................................... 3-4FINAL GEAR OIL ................................................................................................ 3-5COOLANT ............................................................................................................ 3-5



3-2


FUEL OCTANE RATINGUse premium unleaded gasoline withan octane rating of 95 or higher(Research method). Unleaded gaso-line can extend spark plug life andexhaust components life.

(Canada)Your motorcycle requires premiumunleaded gasoline whenever possi-ble, with a minimum pump octane rat-ing of 90 ((R+M)/2 method). In someareas, the only fuels that are availableare oxygenated fuels.

NOTE: • The VZR1800/BZ engine is

designed to use premiumunleaded gasoline only. Use pre-mium unleaded gasoline under allriding conditions.

• If the engine develops some trou-ble like lack of acceleration orinsufficiency of its power, thecause may be due to the fuel themotorcycle uses. In such case, trychanging the gas station toanother. If the situation will not beimproved by changing, consultyour Suzuki dealer for its inspec-tion.

OXYGENATED FUEL RECOMMENDATION(Canada and EU)Oxygenated fuels which meet theminimum octane requirement and therequirements described below maybe used in your motorcycle withoutjeopardizing the New Vehicle LimitedWarranty or the Emission ControlSystem Warranty.

NOTE: Oxygenated fuels are fuelswhich contain oxygen-carrying addi-tives such as MTBE or alcohol.

Gasoline containing MTBEUnleaded gasoline containing MTBE(Methyl Tertiary Butyl Ether) may beused in your motorcycle if the MTBEcontent is not greater than 15%. Thisoxygenated fuel does not containalcohol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline and eth-anol (grain alcohol), also known as“GASOHOL”, may be used in yourmotorcycle if the ethanol content isnot greater than 10%.

Gasoline/Methanol BlendsFuels containing 5% or less methanol(wood alcohol) may be suitable foruse in your motorcycle if they containco-solvents and corrosion inhibitors.



3-3

DO NOT USE fuels containing morethan 5% methanol under any circum-stances. Fuel system damage ormotorcycle performance problemsresulting from the use of such fuelsare not the responsibility of Suzukiand may not be covered under theNew Vehicle Limited Warranty or theEmission Control System Warranty.

NOTE: • To help minimize air pollution,

Suzuki recommends that you useoxygenated fuels.

• Be sure that any oxygenated fuelyou use has recommendedoctane ratings.

• If you are not satisfied with thedrivability of your motorcyclewhen you are using an oxygen-ated fuel, or if engine pinging isexperienced, substitute anotherbrand as there are differencesbetween brands.

NOTICESpilled gasoline containing alco-hol can damage the painted sur-faces of your motorcycle.

Be careful not to spill any fuelwhen filling the fuel tank. Wipespilled gasoline up immediately.

NOTICEDo not use leaded gasoline.

Use of leaded gasoline causes thecatalytic converter to malfunction.



3-4

ENGINE OILUse Suzuki genuine engine oil orequivalent. If Suzuki genuine engineoil is not available, select a properengine oil according to the followingguideline.Oil quality is a major contributor toyour engine’s performance and life.Always select good quality engine oil.Use oil with an API (American Petro-leum Institute) classification of SG orhigher with a JASO classification ofMA.

API: American Petroleum InstituteJASO: Japanese Automobile Stan-dards Organization

SAE Engine Oil ViscositySuzuki recommends the use of SAE10W-40 engine oil. If SAE 10W-40engine oil is not available, select analternative according to the followingchart.

JASO T903The JASO T903 standard is an indexto select engine oils for 4-strokemotorcycle and ATV engines. Motor-cycle and ATV engines lubricateclutch and transmission gears withengine oil. JASO T903 specifies per-formance requirements for motorcy-cle and ATV clutches andtransmissions.

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

1 Code number of oil sales company2 Oil classification

SAE API JASO

10W-40 SG or higher MA



3-5

Energy ConservingSuzuki does not recommend the useof “ENERGY CONSERVING” or“RESOURCE CONSERVING” oils.Some engine oils which have an APIclassification of SH or higher have an“ENERGY CONSERVING” or“RESOURCE CONSERVING” indica-tion in the API classification donutmark. These oils can affect engine lifeand clutch performance.

API SG or higher

Recommended

API from SH to SM API SN or higher

Not recommended

FINAL GEAR OILUse an SAE90 hypoid gear oil whichis rated GL-5 under the API classifica-tion system. If you operate the motor-cycle where ambient temperature isbelow 0°C (32°F), use an SAE80hypoid gear oil.

COOLANTUse “SUZUKI SUPER LONG LIFECOOLANT” or “SUZUKI LONG LIFECOOLANT”. If “SUZUKI SUPERLONG LIFE COOLANT” and“SUZUKI LONG LIFE COOLANT” isnot available, use an glycol-base anti-freeze compatible with aluminum radi-ator mixed with distilled water only atthe ratio of 50:50.

API SERVICE SJ

SAE10W-40

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

RE

SOURCE CONSERVIN

G

AP

I SERVICE SN

SAE10W-40

WARNINGEngine coolant is harmful or fatalif swallowed or inhaled. Solutioncan be poisonous to animals.

Do not drink antifreeze or coolantsolution. If swallowed, do notinduce vomiting. Immediately con-tact a poison control center or aphysician. Avoid inhaling mist orhot vapors; if inhaled, remove tofresh air. If coolant gets in eyes,flush eyes with water and seekmedical attention. Wash thor-oughly after handling. Keep out ofthe reach of children and animals.

NOTICESpilled engine coolant can dam-age the painted surfaces of yourmotorcycle.

Be careful not to spill any fluidwhen filling the radiator. Wipespilled engine coolant up immedi-ately.



3-6

Anti-freezeThe coolant performs as rust inhibitorand water pump lubricant as well asanti-freeze. Therefore the coolantshould be used at all times eventhough the atmospheric temperaturein your area does not go down tofreezing point.

SUZUKI SUPER LONG LIFE COOLANT (Blue)“SUZUKI SUPER LONG LIFE COOL-ANT” is pre-mixed to the proper ratio.Add only “SUZUKI SUPER LONGLIFE COOLANT” if coolant leveldrops. It is not necessary to dilute“SUZUKI SUPER LONG LIFE COOL-ANT” when replacing coolant.

SUZUKI LONG LIFE COOLANT (Green)

Water for mixingUse distilled water only. Water otherthan distilled water can corrode andclog the aluminium radiator.

Required amount of water/coolantSolution capacity (total): 2700 ml(2.9/2.4 US/Imp. qt)

NOTE: This 50% mixture will protectthe cooling system from freezing attemperatures above –31°C (–24°F). Ifthe motorcycle is to be exposed to tem-perature below –31°C (–24°F), this mix-ing ratio should be increased up to 55%(–40°C/–40°F) or 60% (–55°C/–67°F).The mixing ratio should not exceed60%.

50%

Water 1350 ml(1.4/1.2 US/Imp. qt)

Coolant 1350 ml(1.4/1.2 US/Imp. qt)



4-1

4


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



4-2


The opening explains how importantproper break-in is to achieve maxi-mum life and performance from yournew Suzuki. The following guidelinesexplain proper break-in procedures.

MAXIMUM ENGINE SPEED RECOMMENDATIONThis table shows the maximum rec-ommended engine speed during thebreak-in period.

VARY THE ENGINE SPEEDThe engine speed should be variedand not held at a constant speed.This allows the parts to be “loaded”with pressure and then unloaded,allowing the parts to cool. This aidsthe mating process of the parts. It isessential that some stress be placedon the engine components duringbreak-in to ensure this mating pro-cess. Do not, though, apply excessiveload on the engine.

BREAKING IN THE NEW TIRENew tires need proper break-in toassure maximum performance, justas the engine does. Wear in the treadsurface by gradually increasing yourcornering lean angles over the first160 km (100 miles) before attemptingmaximum performance. Avoid hardacceleration, hard cornering, andhard braking for the first 160 km (100miles).

AVOID CONSTANT LOW SPEEDOperating the engine at constant lowspeed (light load) can cause parts toglaze and not seat in. Allow theengine to accelerate freely throughthe gears without exceeding the rec-ommended maximum limits. Do not,however, use full throttle for the first1600 km (1000 miles).

Initial 800 km(500 miles)

Below 3500 rpm

Up to 1600 km(1000 miles)

Below 5500 rpm

Over 1600 km(1000 miles)

Below 7500 rpm

WARNINGFailure to perform break-in of thetires could cause tire slip and lossof control.

Use extra care when riding on newtires. Perform proper break-in ofthe tires as described in this sec-tion and avoid hard acceleration,hard cornering, and hard brakingfor the first 160 km (100 miles).



4-3

ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDINGAllow sufficient idling time after warmor cold engine startup before applyingload or revving the engine. Thisallows time for the lubricating oil toreach all critical engine components.

OBSERVE YOUR FIRST AND MOST CRITICAL SERVICEThe initial service (1000 km mainte-nance) is the most important serviceyour motorcycle will receive. Duringbreak-in operation, all of the enginecomponents will have mated togetherand seated. Maintenance required aspart of the initial service includes cor-rection of all adjustments, tighteningof all fasteners and replacement ofdirty oil. Timely performance of thisservice will help make sure you getthe best service life and performancefrom the engine.

NOTE: The 1000 km (600 miles) ser-vice should be performed as outlinedin the INSPECTION AND MAINTE-NANCE section of this Owner’s Man-ual. Pay particular attention to theCAUTION and WARNING in that sec-tion.

INSPECTION BEFORE RIDING

WARNINGFailure to inspect your motorcy-cle before riding and to properlymaintain your motorcycleincreases the chances of an acci-dent or equipment damage.

Always inspect your motorcycleeach time you use it to make sureit is in safe operating condition.Refer to the INSPECTION ANDMAINTENANCE section in thisowner’s manual.

WARNINGIf you operate this motorcycle withimproper tires or improper oruneven tire pressure, you maylose control of the motorcycle.This will increase your risk of anaccident.

Always use tires of the size andtype specified in this owner’smanual. Always maintain propertire pressure as described in theINSPECTION AND MAINTE-NANCE section.



4-4

Before riding the motorcycle, be sureto check the following items. Neverunderestimate the importance ofthese checks. Perform all of thembefore riding the machine.

WARNINGChecking maintenance itemswhen the engine is running can behazardous. You could be severelyinjured if your hands or clothingget caught in moving engineparts.

Shut the engine off when perform-ing maintenance checks, exceptwhen checking the lights, enginestop switch, and throttle.

WHAT TO CHECK CHECK FOR:

Steering • Smoothness• No restriction of movement• No play or looseness

Throttle( 6-23)

• Correct play in the throttle cable

• Smooth operation and positive return of the throttle grip to the closed position

Clutch( 6-25)

• Correct lever play• Smooth and sure action of

clutch lever

Brakes( 6-30)

• Proper pedal and lever operation

• Fluid level in the reservoir to be above “LOWER” line

• No fluid leakage• Brake pads not to be worn

down to the limit line• Correct pedal and lever

play• No “sponginess”

Suspensions( 2-22)

Smooth movement

Fuel( 2-11)

Enough fuel for the planned distance of operation

Tires( 6-35)

• Correct pressure• Adequate tread depth• No cracks or cut

Engine oil( 6-18)

Correct level

Cooling system( 6-26)

• Proper coolant level• No leaks or damage

Gear oil( 6-29)

Correct level

Horn( 2-15)

Correct function

Engine stop switch( 2-16)

Correct function

Lighting( 2-5, 2-7, 2-13)

Operation of all lights and indicators

Side stand/Ignition interlock system( 6-39)

Proper operation



5-1

5

RIDING TIPS

STARTING THE ENGINE .................................................................................... 5-2STARTING OFF ................................................................................................... 5-3USING THE TRANSMISSION ............................................................................. 5-4RIDING ON HILLS ............................................................................................... 5-5STOPPING AND PARKING ................................................................................ 5-5



5-2

RIDING TIPS

STARTING THE ENGINEBefore attempting to start the enginemake sure:• The transmission is in neutral.• The engine stop switch is in the

“” position.

NOTE: This motorcycle is equippedwith interlock system for the ignitioncircuit and the starter circuit. Theengine 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 theclutch is disengaged.

NOTE: The fuel supply system stopsthe engine when the motorcycle isoverturned. Turn off the ignition switchbefore restarting the engine.

When the engine is cold:1. Close the throttle completely.2. Squeeze the clutch lever and push

the electric starter switch.3. After the engine starts, let the

engine run until the engine suffi-ciently warms up.

When the engine is warm:Close the throttle completely andpush the electric starter switch.

When the engine is hard to start:Open the throttle 1/8 to 1/4 turn andpush the electric starter switch.

WARNINGExhaust gas contains carbonmonoxide, a dangerous gas that isdifficult to detect because it is col-orless and odorless. Breathingcarbon monoxide can cause deathor severe injury.

Never start the engine or let it runindoors or where there is little orno ventilation.

NOTICERunning the engine too long with-out riding may cause the engine tooverheat. Overheating can resultin damage to internal engine com-ponents and discoloration ofexhaust pipes.

Shut the engine off if you cannotbegin your ride promptly.



5-3

STARTING OFF After moving the side stand to thefully up position, squeeze the clutchlever in and pause momentarily.Engage first gear by depressing thegearshift lever downward. Turn thethrottle grip a little toward you and atthe same time release the clutch levergently and smoothly. As the clutchengages, the motorcycle will startmoving forward. To shift to the nexthigher gear, accelerate gently, thenclose the throttle and squeeze theclutch lever in simultaneously. Lift thegearshift lever upward to select thenext gear and release the clutch leverand open the throttle again. Selecthigher gears in this manner until topgear is reached.

NOTE: This motorcycle is equippedwith a side stand/ignition interlocksystem. If you shift the transmissioninto gear when the side stand is downthe engine will stop running.

WARNINGRiding at excessive speedsincreases your chances of losingcontrol of the motorcycle, whichcan result in an accident.

Always ride at a speed that isproper for the terrain, visibilityand operating conditions, andyour skills and experience.

WARNINGIf you remove even one hand orfoot from the motorcycle, you canreduce your ability to control themotorcycle. This could cause youto lose your balance and fall offthe motorcycle. If you remove afoot from a footrest, your foot orleg may come in contact with therear wheels. This could injure youor cause an accident.

Always keep both hands on thehandlebars and both feet on thefootrests of your motorcycle dur-ing operation.

WARNINGSudden side winds, which canoccur when being passed bylarger vehicles, at tunnel exits orin hilly areas, can cause you tolose control of the motorcycle.

Reduce your speed and be alert tothe possibility of sudden sidewinds.



5-4

USING THE TRANSMISSIONThe transmission is provided to keepthe engine operating smoothly in itsnormal operating speed range. Thegear ratios have been carefully cho-sen to meet the characteristics of theengine. The rider should alwaysselect the most suitable gear for theprevailing conditions. Never slip theclutch to control road speed, butrather downshift to allow the engine torun within its normal operationalrange.

(Canada)The table below shows the approxi-mate speed range for each gear.

Shifting up schedule

Shifting down schedule

Disengage the clutch when the motor-cycle speed drops below 20 km/h (12miles/h).

Gear position km/h miles/h

1st → 2nd 20 12

2nd → 3rd 30 19

3rd → 4th 40 25

4th → 5th 50 31

Gear position km/h miles/h

5th → 4th 40 25

4th → 3rd 30 19

WARNINGDownshifting when engine speedis too high can;• cause the rear wheel to skid and

lose traction due to increasedengine braking, resulting in anaccident; or

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

Reduce speed before downshift-ing.

WARNINGDownshifting while the motorcycleis leaned over in a corner maycause rear wheel skid and loss ofcontrol.

Reduce your speed and down-shift before entering a corner.

NOTICERevving the engine into the redzone can cause severe enginedamage.

Never allow the engine to rev intothe red zone in any gear.

NOTICEImproper gearshift lever opera-tion can damage the transmission.

• Do not rest your foot on thegearshift lever.

• Do not force to shift gears.



5-5

RIDING ON HILLS• When climbing steep hills, the

motorcycle may begin to slowdown and show lack of power. Atthis point you should shift to alower gear so that the engine willagain be operating in its normalpower range. Shift rapidly to pre-vent the motorcycle from losingmomentum.

• When riding down a steep hill, theengine may be used for braking byshifting to a lower gear.

• Be careful, however, not to allowthe engine to overrev.

STOPPING AND PARKING1. Turn the throttle grip away from

you to close the throttle com-pletely.

2. Apply the front and rear brakesevenly and at the same time.

3. Downshift through the gears asroad speed decreases.

4. Select neutral with the clutch leversqueezed towards the grip (disen-gaged position) just before themotorcycle stops. The neutralposition can be confirmed byobserving the neutral indicatorlight.

WARNINGInexperienced riders tend tounderutilize the front brake. Thiscan cause excessive stopping dis-tance and lead to a collision.Using only the front or rear brakecan cause skidding and loss ofcontrol.

Apply both brakes evenly and atthe same time.

WARNINGHard braking while turning maycause wheel skid and loss of con-trol.

Brake before you begin to turn.



5-6

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

NOTE: If the motorcycle is to beparked on the side stand on a slightslope, the front end of the motorcycleshould face “up” the incline to avoidrolling forward off the side stand. Youmay leave the motorcycle in 1st gearto help prevent it from rolling off theside stand. Shift to neutral beforestarting engine.

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

7. Turn the handlebars all the way tothe left and lock the steering forsecurity.

8. Remove the keys.

NOTE: If an optional anti-theft locksuch as U-shape lock, brake disk lockand chain is used to avoid theft, besure to remove the anti-theft lockbefore moving the motorcycle.

WARNINGHard braking on wet, loose, rough,or other slippery surfaces cancause wheel skid and loss of con-trol.

Brake lightly and with care on slip-pery or irregular surfaces.

WARNINGFollowing another vehicle tooclosely can lead to a collision. Asvehicle speeds increase, stop-ping distance increases progres-sively.

Always maintain a safe stoppingdistance between you and thevehicle in front of you.

NOTICEHolding the motorcycle stoppedwith throttle and clutch lever oper-ation on inclines can damage themotorcycle’s clutch.

Use the brakes when stopping themotorcycle on inclines.

CAUTIONA hot muffler can cause severeburns. The muffler will be hotenough to cause burns for sometime after stopping the engine.

Park the motorcycle where pedes-trians or children are not likely totouch the muffler.



6-1

6


MAINTENANCE SCHEDULE .............................................................................. 6-2TOOLS ................................................................................................................. 6-7LUBRICATION POINTS ...................................................................................... 6-7BATTERY ............................................................................................................ 6-8AIR CLEANER ................................................................................................... 6-10SPARK PLUGS ................................................................................................. 6-13ENGINE OIL ....................................................................................................... 6-18THROTTLE CABLE ADJUSTMENT ................................................................. 6-23ENGINE IDLE SPEED INSPECTION ................................................................ 6-24FUEL HOSE ....................................................................................................... 6-25CLUTCH ADJUSTMENT ................................................................................... 6-25COOLANT .......................................................................................................... 6-26FINAL GEAR OIL .............................................................................................. 6-29BRAKES ............................................................................................................ 6-30TIRES ................................................................................................................. 6-35SIDE STAND/IGNITION INTERLOCK SYSTEM ............................................... 6-39FRONT WHEEL REMOVAL .............................................................................. 6-40REAR WHEEL REMOVAL ................................................................................ 6-42LIGHT BULB REPLACEMENT ......................................................................... 6-44FUSES ............................................................................................................... 6-48CATALYTIC CONVERTER ............................................................................... 6-49



6-2


MAINTENANCE SCHEDULEThe chart indicates the intervalsbetween periodic services in miles,kilometers and months. At the end ofeach interval, be sure to inspect,check, lubricate and service asinstructed. If your motorcycle is usedunder high stress conditions such ascontinuous full throttle operation, or isoperated in a dusty climate, certainservices should be performed moreoften to ensure reliability of themachine as explained in the mainte-nance section. Your authorizedSuzuki dealer can provide you withfurther guidelines. Steering compo-nents, suspension and wheel compo-nents are key items and require veryspecial and careful servicing. Formaximum safety we suggest that youhave these items inspected and ser-viced by your authorized Suzukidealer or a qualified servicemechanic.

WARNINGImproper maintenance or failureto perform recommended mainte-nance can lead to an accident.

Keep your motorcycle in goodcondition. Ask your Suzuki dealeror a qualified mechanic to performthe maintenance items markedwith an asterisk (*). You may per-form the unmarked maintenanceitems by referring to the instruc-tions in this section, if you havemechanical experience. If you arenot sure how to do any of the jobs,ask your Suzuki dealer to do themaintenance.

WARNINGExhaust gas contains carbonmonoxide, a dangerous gas that isdifficult to detect because it is col-orless and odorless. Breathingcarbon monoxide can cause deathor severe injury.

Never start the engine or let it runindoors or where there is little orno ventilation.



6-3

NOTE: The MAINTENANCE CHARTspecified the minimum requirementsfor maintenance. If you use yourmotorcycle under severe conditions,perform maintenance more often thanshown in the chart. If you have anyquestions regarding maintenanceintervals, consult your Suzuki dealeror a qualified mechanic.

NOTICEServicing electric parts with theignition switch in the “ON” posi-tion can damage the electric partswhen the electric circuit isshorted.

Turn off the ignition switch beforeservicing the electric parts toavoid short-circuit damage.

NOTICEPoorly-made replacement partscan cause your motorcycle towear more quickly and mayshorten its useful life.

When replacing parts on yourvehicle, use only genuine Suzukireplacement parts or their equiva-lent.



6-4

MAINTENANCE CHARTInterval: This interval should be judged by number of months or odometerreading, whichever comes first.

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

Element

Interval months 2 12 24 36 48

km 1000 6000 12000 18000 24000

miles 600 4000 7500 11000 14500

Air cleaner element ( 6-10) – I I R I

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

* Exhaust control valve I – I – I

* Valve clearance – – – – I

Spark plugs ( 6-13) – I R I R

Fuel hose ( 6-25) – I I I I

Engine oil ( 6-18) R R R R R

Engine oil filter ( 6-18) R – – R –

Final gear oil ( 6-29) R – I – I

Throttle cable play ( 6-23) I I I I I

* PAIR (air supply) system – – I – I

* Throttle valve synchronization – – I – I

* Engine coolant ( 6-26)

“SUZUKI SUPER LONG LIFE COOLANT” (Blue)

Replace every 4 years or 48000 km (29000 miles)

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

– – R – R

Radiator hose ( 6-28) – I I I I

Clutch cable play ( 6-25) – I I I I

* Brakes ( 6-30) I I I I I

Brake hose ( 6-30)– I I I I

* Replace every 4 years

Brake fluid ( 6-31)– I I I I


Tires ( 6-35) – I I I I

* Steering I – I – I

* Front forks – – I – I

* Rear suspension ( 2-22) – – I – I

* Chassis bolts and nuts T T T T T

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



6-5

For Europe and Oceania countries

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

Element

Interval months 2 12 24 36 48

km 1000 12000 24000 36000 48000

miles 600 7500 15000 22500 30000

Air cleaner element ( 6-10) – I I R I

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

* Exhaust control valve I – I – I

* Valve clearance Inspect every 24000 km (15000 miles)

Spark plugs ( 6-13) – R R R R

Fuel hose ( 6-25) – I I I I

Engine oil ( 6-18) R R R R R

Engine oil filter ( 6-18) R – R – R

Final gear oil ( 6-29) R – I – I

Throttle cable play ( 6-23) I I I I I

* PAIR (air supply) system – – I – I

* Throttle valve synchronization – I I I I

* Engine coolant ( 6-26)

“SUZUKI SUPER LONG LIFE COOLANT” (Blue)

– – – – R

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

– – R – R

Radiator hose ( 6-28) – I I I I

Clutch cable play ( 6-25) – I I I I

* Brakes ( 6-30) I I I I I

Brake hose ( 6-30)– I I I I


Brake fluid ( 6-31) Inspect every year or 6000 km (4000 miles)*Replace every 2 years

Tires ( 6-35) – I I I I

* Steering I I I I I

* Front forks – I I I I

* Rear suspension ( 2-22) – I I I I

* Chassis bolts and nuts T T T T T

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



6-6Downloaded from www.Manualslib.com manuals search engine


6-7

TOOLS

A tool kit is provided with your motor-cycle. The toolbox is located underthe seat.

LUBRICATION POINTSProper lubrication is important forsmooth and long life of each workingpart of your motorcycle and also forsafe riding. It is a good practice tolubricate the machine after a longrough ride and after it gets wet in therain or after washing it. Major lubrica-tion points are as follows:

.... Motor oil .... Grease

1 Clutch lever pivot2 Gearshift link pivots3 Side stand pivot and spring hook4 Throttle cable5 Brake lever pivot6 Brake pedal pivot and

brake rod link

NOTICELubricating electrical switchescan damage the switches.

Do not apply grease and oil toelectrical switches.



6-8

BATTERYThis battery is a sealed type batteryand requires no maintenance. Haveyour dealer check the battery’s stateof charge periodically.

The standard charging rate is 1.8A ×5 to 10 hours and the maximum rateis 9.0A × 1 hour. Never exceed maxi-mum charging rate.

WARNINGBattery posts, terminals, andrelated accessories contain leadand lead compounds. Lead isharmful to your health if it getsinto your blood stream.

Wash hands after handling anyparts containing lead.

WARNINGDiluted sulfuric acid from batterycan cause blindness or severeburns.

When working near the battery,use proper eye protection andgloves. Flush eyes or body withample water and get medical careimmediately if you suffer injury.Keep batteries out of reach of chil-dren.

WARNINGBatteries produce flammablehydrogen gas which can explodeif exposed to flames or sparks.

Keep flames and sparks awayfrom the battery. Never smokewhen working near the battery.

NOTICEExceeding the maximum chargingrate for the battery can shorten itslife.

Never exceed the maximum charg-ing rate for the battery.

WARNINGWiping the battery with a dry clothcan cause a static electricityspark, which can start a fire.

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



6-9

BATTERY REMOVALTo remove the battery, follow proce-dure below:1. Place the motorcycle on the side

stand.2. Remove the front seat by referring

to the SEAT LOCK section.

3. Remove the fasteners 1 andcover 2.

4. Disconnect the negative (–) termi-nal 3.

5. Remove the cap. Disconnect thepositive (+) terminal 4.

6. Remove the battery 5.

To install the battery:1. Install the battery in the reverse

order of removal.2. Connect the battery terminals

securely.

NOTE: • Select the same type MF battery

when replacing the battery.• Recharge the battery once a

month if the motorcycle is notused for a long time.

NOTICEReversing the battery lead wirescan damage the charging systemand the battery.

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

WARNINGBatteries contain toxic sub-stances including sulfuric acidand lead. They could cause injuryto humans or could damage theenvironment.

A used battery must be disposedof or recycled according to locallaw and must not be discardedwith ordinary household waste.Make sure not to tip over the bat-tery when you remove it from thevehicle. Otherwise, sulfuric acidcould run out and you might beinjured.



6-10

The crossed-out wheeled bin symbolA located on the battery label indi-cates that used battery should be col-lected separately from ordinaryhousehold waste.The chemical symbol of “Pb” B indi-cates the battery contains more than0.004% lead.

By ensuring the used battery is dis-posed of or recycled correctly, you willhelp prevent potential negative conse-quences for the environment andhuman health, which could otherwisebe caused by inappropriate wastehandling of the battery. The recyclingof materials will help to conserve nat-ural resources. For more detailedinformation about disposing or recy-cling of the used battery, consult yourSuzuki dealer.

AIR CLEANERIf the elements have become cloggedwith dust, intake resistance willincrease with a resultant decrease inpower output and an increase in fuelconsumption. If you use your motor-cycle under normal low-stress condi-tions, you should service the aircleaner at the intervals specified. Ifyou ride in dusty, wet or muddy condi-tions, you will need to inspect the aircleaner element much more fre-quently. Use the following procedureto remove the element and inspect it.

Pb

WARNINGOperating the engine without theair cleaner element in place can behazardous. A flame can spit backfrom the engine to the air intakebox without the air cleaner ele-ment to stop it. Severe enginedamage can also occur if dirtenters the engine due to runningthe engine without the air cleanerelement.

Never run the engine without theair cleaner element in place.



6-11


2. Remove the bolts 1 and unhookthe hook 2.

3. Loosen the clamp screw 3 andremove the air cleaner 4.

4. Disconnect the drain tube 5.

5. Remove the screws. Remove theair cleaner case 6.

NOTICEFailure to inspect the air cleanerelement frequently if the vehicle isused in dusty, wet, or muddy con-ditions can damage your motorcy-cle. The air cleaner element canbecome clogged under these con-ditions, and engine damage mayresult.

Always inspect the air cleaner ele-ment after riding in severe condi-tions. Clean or replace theelement as necessary. If watergets in the air cleaner case, imme-diately clean the element and theinside of the case.



6-12

6. Remove the screws. Remove theair cleaner element 7.

7. Carefully use an air hose to blowthe dust from the air cleaner ele-ment.

NOTE: Always apply air pressure tothe mesh side of the air cleaner ele-ment only. If you apply air pressure tothe fabric side, dirt will be forced intothe pores of the element, restrictingthe air flow through the element.

8. Reinstall the air cleaner elementin reverse order of removal. Beabsolutely sure that the element issecurely in position and is sealingproperly.

NOTE: Be careful not to spray wateron the air cleaner box when cleaningthe motorcycle.

NOTICEA torn air cleaner element willallow dirt to enter the engine andcan damage the engine.

Replace the air cleaner elementwith a new one if it is torn. Care-fully examine the air cleaner ele-ment for tears during cleaning.

NOTICEFailure to position the air cleanerelement properly can allow dirt tobypass the air cleaner element.This will cause engine damage.

Be sure to properly install the aircleaner element.



6-13

AIR CLEANER DRAIN PLUG

Remove the plug and drain water andoil at the periodic maintenance inter-val. The air cleaner drain plug islocated beneath the air cleaner box.

SPARK PLUGSSPARK PLUG REMOVAL1. Place the motorcycle on the side

stand.2. Remove the front seat by referring

to the SEAT LOCK section.

3. Remove the bolts 1.

4. Disconnect the coupler 2 andfuel hose 3.



6-14

5. Disconnect the speedometer cou-pler 4.

6. Remove the fuel tank.

NOTE: Do not lift the fuel tank toomuch, or the fuel hose will be bent ortwisted.

7. Remove the fastener 5 andscrew 6.

8. Remove the bolts 7 and fastener8. Unhook the hooks. Removethe frame cover 9.



6-15

FRONT

REAR

9. Release the connector locks anddisconnect the connectors fromthe ignition coils.

10. Pull off the ignition coils.

11. Remove the spark plug with aspark plug wrench.

NOTE: Pry up the ignition coils with ascrewdriver or a bar if it is hard toremove by hand. Do not pull the sparkplug cord.

12. Remove the rear brake reservoirbracket bolt 0.

NOTICEImproper removal of ignition coilscan damage the ignition coils.

Pull off the ignition coils with yourhand. Do not use pliers.

NOTICEDirt can damage the movingengine parts of your motorcycle ifit enters an open spark plug hole.

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



6-16

FRONT

REAR

13. Pull off the cover.14. Pull off the spark plug cap.15. Remove the spark plug with a

spark plug wrench.



6-17

SPARK PLUG CLEANING

Readjust the spark plug gap to 0.6 –0.7 mm (0.024 – 0.028 in) with aspark plug gap thickness gauge. Thespark plug should be replaced every12000 km (7500 miles).

Before removing the carbon deposits,observe the color of the porcelain tipof each spark plug. This color tellsyou whether or not the standard sparkplug is suitable for your type of usage.If the standard plug is wet appearingor dark in color, the hotter spark plugmay be more suitable. A normally-operating spark plug should be lightbrown in color. If the spark plug iswhite or glazed appearing then it hasbeen operating much too hot. Thisspark plug should be replaced with acolder plug.

PLUG REPLACEMENT GUIDE

NOTE: This motorcycle uses a resis-tor-type spark plug to avoid jammingelectronic parts. Improper spark plugselection may cause electronic inter-ference with your motorcycle’s ignitionsystem, resulting in motorcycle per-formance problems. Use only the rec-ommended spark plugs.

0.6 – 0.7 mm

NOTICEAn improper spark plug may havean incorrect fit or inappropriateheat range for your engine. Thismay cause severe engine damagewhich may not be covered underwarranty.

Use one of the spark plugs listedor their equivalent. Consult yourSuzuki dealer if you are not surewhich spark plug is correct foryour type of usage.

NGK DENSO REMARKS

CR7EK U22ETR

If the standard plug is apt to get wet, replace with this plug.

CR8EK U24ETR Standard

CR9EK U27ETR

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



6-18

INSTALLATION ENGINE OILLong engine life depends much onthe selection of a quality oil and theperiodic changing of the oil. Daily oillevel checks and periodic changesare two of the most important mainte-nance items to be performed.

ENGINE OIL LEVEL CHECK

Check the engine oil level with theengine oil dipstick. The dipstickcomes out together with the oil fillercap as shown. The level on the dip-stick should be between the “L” (Low)and “F” (Full) lines.

NOTE: It is not necessary to fill theengine oil up to the “F” (Full) linewhen the oil level is above the “L”(Low) line. If the oil level is out of therange, adjust the oil level at the mid-dle point between “F” and “L”.

NOTICEImproper installation of the sparkplug can damage your motorcycle.An overly-tight or cross-threadedspark plug will damage the alumi-num threads of the cylinder head.

Carefully turn the spark plug byhand into the threads. If the sparkplug is new, tighten it with awrench about 1/2 turn past fingertight. If you are reusing the oldspark plug, tighten it with awrench about 1/8 turn past fingertight.

NOTICEDirt can damage the movingengine parts of your motorcycle ifit enters an open spark plug hole.

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

CAUTIONExhaust pipes can be hot enoughto burn you.

Use gloves to avoid burns.

FL



6-19

This motorcycle has two crankcasechambers: crankshaft chamber andtransmission chamber. The engine oilmoves from chamber to chamber andit takes time to obtain correct engineoil level when the engine is started.The engine oil level inspection shouldbe performed under the following con-ditions:


2. Start the engine and allow it to idlefor about 15 minutes. If the engineis cold, warm up the engine suffi-ciently.

NOTE: • Engine oil level cannot be mea-

sured correctly when the engine isnot warmed up sufficiently.

• Be sure to keep the engine speedat idling.

3. Hold the motorcycle vertically andallow it to idle for 30 seconds.

4. Place the motorcycle on the sidestand and allow it to idle for 10seconds.

5. Stop the engine and wait approxi-mately three minutes.

6. Remove the oil dipstick and cleanthe dipstick.

7. Hold the motorcycle vertically.Insert the oil dipstick through theoil filler hole. The oil filler capthreads should not be run in butshould be touching the filler holeupper edge.

8. Pull out the oil dipstick and inspectthe oil level.

9. Refit the oil dipstick.

NOTICEOperating the motorcycle with toolittle or too much oil can damagethe engine.

Place the motorcycle on levelground. Check the oil level withthe engine oil dipstick before eachuse of the vehicle. Be sure theengine oil level is always abovethe “L” (low) line and not higherthan the “F” (full) line.



6-20

ENGINE OIL AND FILTER CHANGEChange the engine oil and oil filter atthe scheduled time. The oil should bechanged when the engine is warm sothat the oil will drain thoroughly fromthe engine. The procedure is as fol-lows:


2. Remove the oil filler cap 1.

3. Place a drain pan under the drainplugs.

4. Remove the drain plugs 2 andgaskets 3 with a wrench anddrain out the engine oil while hold-ing the motorcycle vertically.

NOTE: Recycle or properly dispose ofused oil.

CAUTIONHot engine oil and exhaust pipescan burn you.

Wait until the oil drain plug andexhaust pipes are cool enough totouch with bare hands beforedraining oil.

WARNINGChildren and pets may be harmedby swallowing new or used oil.Repeated, prolonged contact withused engine oil may cause skincancer. Brief contact with oil mayirritate skin.

Keep new and used oil and usedoil filters away from children andpets. To minimize your exposureto used oil, wear a long-sleeveshirt and moisture-proof gloves(such as dishwashing gloves)when changing oil. If oil contactsyour skin, wash thoroughly withsoap and water. Launder anyclothing or rags if wet with oil.Recycle or properly dispose ofused oil and filters.



6-21

Oil filter wrench(Part No. 09915-40620)

5. Turn the oil filter 4 counterclock-wise and remove it with a Suzuki“cap type” oil filter wrench or a“strap type” filter wrench of theproper size.

6. Wipe off the mounting surface 5on the engine where the new filterwill be seated with a clean rag.

7. Smear a little engine oil aroundthe rubber gasket 6 of the new oilfilter.

8. Screw the new filter by hand untilthe filter gasket contacts themounting surface (a small resis-tance will be felt).

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

NOTICEFailure to use an oil filter with thecorrect design and thread specifi-cations can damage your motor-cycle’s engine.

Be sure to use a genuine Suzukioil filter or an equivalent onedesigned for your motorcycle.



6-22

9. Mark the top dead center positionon the “cap type” filter wrench oron the oil filter. Use an oil filterwrench to tighten the filter 2 turnsor to specified torque.

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

10. Replace the gaskets with newones. Reinstall the drain plugsand gaskets. Tighten the plugsecurely with a torque wrench.Pour about 3000 ml (3.2/2.8 US/Imp qt) of the specified oil in thefiller hole. Tighten the oil filler cap.Start the engine and allow it to idlefor a few minutes.

Drain plug tightening torque:23 N·m (2.3 kgf-m, 16.5 lbf-ft)

11. Remove the oil filler cap. Pourremaining engine oil in the fillerhole. Tighten the oil filler cap.Start the engine and allow it to idlefor a few minutes.

NOTE: About 3600 ml (3.8/3.2 US/Imp qt) of oil will be required when theengine oil and oil filter are changed.About 3400 ml (3.6/3.0 US/Imp qt) ofoil will be required when changing oilonly.

Mark top dead center

Oil filter wrench

In the position at which the filtergasket first contactsthe mountingsurface.

Tighten the filter 2 turns or to specified torque.



6-23

12. Check the oil level according to OilLevel Check procedure.

NOTE: Check to see that no oil isleaking from the oil filter cover.

THROTTLE CABLE ADJUSTMENT

To adjust the cable play:1. Loosen the lock nut 1.2. Turn the adjuster 2 so that the

throttle grip has 2.0 – 4.0 mm(0.08 – 0.16 in) play.

3. Tighten the lock nut 1.

NOTICEEngine damage may occur if youuse oil that does not meetSuzuki’s specifications.

Be sure to use the oil specified inthe FUEL, OIL AND ENGINECOOLANT RECOMMENDATIONSsection.

WARNINGInadequate throttle cable play cancause engine speed to rise sud-denly when you turn the handle-bars. This can lead to loss ofcontrol and an accident.

Adjust the throttle cable play sothat engine idle speed does notrise due to handlebar movement.

2.0 – 4.0 mm



6-24

THROTTLE CABLE BOOTS

The throttle cable has boots. Checkthat the boots are fit securely. Do notapply water directly to the boots whenwashing. Wipe off dirt from the bootswith a wet cloth when the boots aredirty.

ENGINE IDLE SPEED INSPECTIONInspect the engine idle speed. Theengine idle speed should be 800 –1000 r/min when the engine is warm.

NOTE: If the engine idle speed is notwithin the specified range, ask yourSuzuki dealer or a qualified mechanicto inspect and repair the motorcycle.



6-25

FUEL HOSE

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

NOTE: Lifting up the fuel tank toomuch can result in the fuel hosebecoming bent or twisted. Lift the fueltank as little as possible and discon-nect the fuel hose. The fuel tank inthe above illustration is lifted to showthe fuel hose and coupler clearly.

CLUTCH ADJUSTMENTClutch cable play should be 10 – 15mm (0.4 – 0.6 in) measured at theclutch lever end. Adjust clutch cableplay according to the following proce-dure:

Minor Adjustment

Loosen the lock nut 2. Turn theclutch cable adjuster 1 to provide thespecified play.

10 – 15 mm



6-26

Major Adjustment

1. Remove the 3 bolts.

2. Loosen the lock nuts 3 and turnthe nuts to obtain the correctclutch lever play.

3. Minor adjustments can be madewith the clutch lever side adjuster1.

4. Tighten the lock nuts 2 and 3.

NOTE: Any maintenance of the clutchother than the clutch cable playadjustment should be performed byyour Suzuki dealer.

COOLANTCOOLANT LEVEL

The coolant should be kept betweenthe “F” (FULL) and “L” (LOW) levellines in the reservoir tank at all times.Inspect the level every time beforeriding with the motorcycle held verti-cally. If the coolant is found lower thanthe “L” level line, add specified enginecoolant in the following way:

NOTE: • Check the coolant level when the

engine is cold.• If the engine coolant reservoir is

empty, check the radiator coolantlevel.


2. Remove the fuel tank by referringto the SPARK PLUG REMOVALsection.

F

L

F

L



6-27

3. Remove the fastener 1 andscrew 2.

4. Remove the bolts 3 and fastener4. Unhook the hooks. Removethe frame cover 5.

5. Remove the filler cap and addspecified engine coolant throughthe filler hole until it reaches the“F” line. Refer to the FUEL, OILAND COOLANT RECOMMENDA-TIONS section.



6-28

NOTE: Adding only water will dilutethe engine coolant and reduce itseffectiveness. Add specified enginecoolant.

CHANGING THE COOLANTChange the coolant periodically.

NOTE: About 2700 ml (2.9/2.4 US/Imp. pt) of coolant will required whenfilling the radiator and reservoir tank.

RADIATOR HOSE INSPECTIONInspect the radiator hoses for cracks,damage or engine coolant leakage. Ifany defects are found, ask yourSuzuki dealer to replace the radiatorhose with a new one.

WARNINGEngine coolant is harmful or fatalif swallowed or inhaled. Solutioncan be poisonous to animals.

Do not drink antifreeze or coolantsolution. If swallowed, do notinduce vomiting. Immediately con-tact a poison control center or aphysician. Avoid inhaling mist orhot vapors; if inhaled, remove tofresh air. If coolant gets in eyes,flush eyes with water and seekmedical attention. Wash thor-oughly after handling. Keep out ofthe reach of children and animals.



6-29

FINAL GEAR OILChange the gear oil at initial 1000 km(600 miles) and inspect every 12000km (7500 miles). Use SAE90 hypoidgear oil which is rated GL-5 under APIclassification system. If you operatethe motorcycle where ambient tem-perature is below 0°C (32°F) use SAE80 hypoid gear oil. The procedure isas follows:


2. Remove the oil filler cap 1.3. Drain the oil by removing the drain

plug 2 into a suitable containerfrom the bottom of the final gearcase while holding the motorcyclevertically.

4. Reinstall the drain plug andtighten it securely after all the oilhas been drained out. Pour freshoil through the filler hole until theoil level reaches the oil filler holewhile holding the motorcycle verti-cally. Approximately 200 – 220 ml(6.8 – 7.4/7.0 – 7.7 US/Imp oz) ofoil will be required.

5. Reinstall the oil filler cap.

NOTE: Recycle or properly dispose ofused oil.

WARNINGOperating the motorcycle with toolittle final gear oil can cause thefinal drive unit to lock up andcause an accident.

Check for leaks and the correctlevel of final gear oil before eachuse. Add oil if necessary. Tightenthe drain plug securely afterchanging the gear oil.

WARNINGChildren and pets may be harmedby swallowing new or used oil.Repeated, prolonged contact withused engine oil may cause skincancer. Brief contact with oil mayirritate skin.

Keep new and used oil and usedoil filters away from children andpets. To minimize your exposureto used oil, wear a long-sleeveshirt and moisture-proof gloves(such as dishwashing gloves)when changing oil. If oil contactsyour skin, wash thoroughly withsoap and water. Launder anyclothing or rags if wet with oil.Recycle or properly dispose ofused oil and filters.



6-30

BRAKESThis motorcycle utilizes front and reardisk brakes. Proper operation ofbrake systems are vital to safe riding.Be sure to perform the brake inspec-tion as scheduled.

BRAKE SYSTEM

Inspect your brake system for the fol-lowing items daily:• Inspect the fluid level in the reser-

voirs.• Inspect the front and rear brake

system for signs of fluid leakage.• Inspect the brake hose for leak-

age or a cracked appearance.• The brake lever and pedal should

have the proper stroke and be firmat all times.

• Check the wear of the disk brakepads.

BRAKE HOSE INSPECTIONInspect the brake hoses and hosejoints for cracks, damage or brakefluid leakage. If any defects are found,ask your Suzuki dealer to replace thebrake hose with a new one.

WARNINGFailure to properly inspect andmaintain your motorcycle’s brakesystems can increase your chanceof having an accident.

Be sure to inspect the brakesbefore each use according to theINSPECTION BEFORE RIDINGsection. Always maintain yourbrakes according to the MAINTE-NANCE SCHEDULE.



6-31

BRAKE FLUID

FRONT

REAR

Check the brake fluid level in both thefront and rear brake fluid reservoirs.Inspect for brake pad wear and leaks.

WARNINGBrake fluid will gradually absorbmoisture through the brake hoses.Brake fluid with high water con-tent lowers the boiling point andcan cause brake system malfunc-tion due to corrosion of brakecomponents. Boiling brake fluidor brake system malfunctioncould result in an accident.

Replace the brake fluid every twoyears to maintain braking perfor-mance.

WARNINGThe use of any fluid except DOT4brake fluid from a sealed con-tainer can damage the brake sys-tem and lead to an accident.

Clean filler cap before removing.Use only DOT4 brake fluid from asealed container. Never use or mixwith different types of brake fluid.



6-32

BRAKE PADS

FRONT

REAR

FRONT REAR

WARNINGBrake fluid is harmful or fatal ifswallowed, and harmful if it comesin contact with skin or eyes. Solu-tion can be poisonous to animals.

If brake fluid is swallowed, do notinduce vomiting. Immediately con-tact a poison control center or aphysician. If brake fluid gets ineyes, flush eyes with water andseek medical attention. Wash thor-oughly after handling. Keep out ofthe reach of children and animals.

NOTICESpilled brake fluid can damagepainted surfaces and plastic parts.

Be careful not to spill any fluidwhen filling the brake fluid reser-voir. Wipe spilled fluid up immedi-ately.



6-33

Inspect the front and rear brake padsby noting whether or not the frictionpads are worn down to the groovedwear limit line 1. If a front or rear padis worn to the grooved wear limit lineboth front or both rear pads must bereplaced with new ones by yourauthorized Suzuki dealer or qualifiedservice mechanic.

NOTE: Do not squeeze/depress thebrake lever/pedal when the pads arenot in their positions. It is difficult topush the pistons back and brake fluidleakage may result.

WARNINGFailure to inspect and maintain thebrake pads and replace themwhen recommended can increaseyour chance of having an acci-dent.

If you need to replace brake pads,have your Suzuki dealer do thiswork. Inspect and maintain thebrake pads as recommended.

WARNINGIf you ride this motorcycle afterbrake system repair or brake padreplacement without pumping thebrake lever/pedal, you may getpoor braking performance whichcould result in an accident.

After brake system repair or brakepad replacement, pump the brakelever/pedal several times untilbrake pads are pressed againstthe brake disks and proper lever/pedal stroke and firm feel arerestored.

WARNINGReplacing only one of the twobrake pads can result in unevenbraking action and can increaseyour chance of having an acci-dent.

Always replace both padstogether.



6-34

REAR BRAKE PEDAL ADJUSTMENT

The rear brake pedal position must beproperly adjusted at all times or thedisk brake pads will rub against thedisk causing damage to the pads andto the disk surface. Adjust the brakepedal position in the following man-ner:

1. Loosen the lock nut 1, and turnthe push rod 2 to locate the pedal15 – 25 mm (0.6 – 1.0 in) abovethe top face of the footrest.

2. Retighten the lock nut 1 tosecure the push rod 2 in theproper position.

CAUTIONA hot muffler can burn you. Themuffler will be hot enough to burnyou for some time after stoppingthe engine.

Wait until the muffler cools toavoid burns.

NOTICEAn incorrectly adjusted brakepedal may force brake pads to rubagainst the disk at all times, caus-ing damage to the pads and disk.

Follow the steps in this section toadjust the brake pedal properly.

15 – 25 mm



6-35

REAR BRAKE LIGHT SWITCH

To adjust the brake light switch, holdthe switch body and turn the adjusterso that the brake light will come onjust before a pressure rise is felt whenthe brake pedal is depressed.

TIRES

WARNINGThe tires on your motorcycle formthe crucial link between yourmotorcycle and the road. Failureto take the precautions below mayresult in an accident due to tirefailure.

• Check tire condition and pres-sure before each ride, andadjust pressure if necessary.

• Avoid overloading your motor-cycle.

• Replace a tire when worn to thespecified limit, or if you finddamage such as cuts or cracks.

• Always use the size and type oftires specified in this owner’smanual.

• Balance the wheel after tireinstallation.

• Read this section of the owner’smanual carefully.



6-36

TIRE PRESSURE AND LOADINGProper tire pressure and proper tireloading are important factors. Over-loading your tires can lead to tire fail-ure and loss of motorcycle control.

Check tire pressure each day beforeyou ride, and be sure the pressure iscorrect for the motorcycle loadaccording to the following table. Tirepressure should only be checked andadjusted before riding since riding willheat up the tires and lead to higherinflation pressure readings.

Cold tire inflation pressure

Under-inflated tires make smooth cor-nering difficult, and can result in rapidtire wear. Over-inflated tires causesmaller amount of tire to be in contactwith the road, which can contribute toskidding and loss of control.

NOTE: When you detect drops in tirepressure, check the tire for nails orother punctures, or a damaged wheelrim. Tubeless tires sometimes losepressure gradually when punctured.

WARNINGFailure to perform break-in of thetires could cause tire slip and lossof control, which could result in anaccident.

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

LOAD

TIRE

SOLO RIDING WITH LIGHT OR LITTLE

CARGO LOAD

DUAL RIDING OR SOLO

RIDING WITH HEAVY

CARGO LOAD

FRONT250 kPa

2.50 kgf/cm2 36 psi

250 kPa 2.50 kgf/cm2

36 psi

REAR290 kPa

2.90 kgf/cm2 42 psi

290 kPa 2.90 kgf/cm2

42 psi



6-37

TIRE CONDITION AND TYPEProper tire condition and proper tiretype affect motorcycle performance.Cuts or cracks in the tires can lead totire failure and loss of motorcycle con-trol. Worn tires are susceptible topuncture failures and subsequent lossof motorcycle control. Tire wear alsoaffects the tire profile changing motor-cycle handling characteristics.

Check the condition of your tires eachday before you ride. Replace tires iftires show visual evidence of damage,such as cracks or cuts, or if treaddepth is less than 1.6 mm (0.06 in)front, 2.0 mm (0.08 in) rear.

NOTE: The “Triangle mark” indicatesthe place where the wear bars aremolded into the tire. When the wearbars contact the road, it indicates thatthe tire wear limit has been reached.

Whenever you replace a tire, use atire of the size and type listed below. Ifyou use a different size or type of tire,motorcycle handling may beadversely affected, possibly resultingin loss of motorcycle control.

Always balance the wheel afterrepairing a puncture or replacing thetire. Proper wheel balance is impor-tant to avoid variable wheel-to-roadcontact, and to avoid uneven tirewear.

FRONT REAR

SIZE 130/70R18M/C63V

240/40R18M/C79V

TYPE DUNLOP D221FA

DUNLOP D221



6-38

WARNINGAn improperly repaired, installed,or balanced tire can cause loss ofcontrol and an accident, or canwear out sooner.

• Ask your Suzuki dealer or aqualified mechanic to performtire repair, replacement, and bal-ancing because proper toolsand experience are required.

• Install tires according to therotation direction shown byarrows on the sidewall of eachtire.

WARNINGFailure to follow the instructionsbelow for tubeless tires may resultin an accident due to tire failure.Tubeless tires require differentservice procedures than tubetires.

• Tubeless tires require an air-tight seal between the tire beadand wheel rim. Special tire ironsand rim protectors or a special-ized tire mounting machinemust be used for removing andinstalling tires to prevent tire orrim damage which could resultin an air leak.

• Repair punctures in tubelesstires by removing the tire andapplying an internal patch.

• Do not use an external repairplug to repair a puncture sincethe plug may work loose as aresult of the cornering forcesexperienced by a motorcycletire.

• After repairing a tire, do notexceed 80 km/h (50 mph) for thefirst 24 hours, and do notexceed 130 km/h (80 mph) there-after. This is to avoid excessiveheat build-up which could resultin a tire repair failure and tiredeflation.

• Replace the tire if it is puncturedin the sidewall area, or if a punc-ture in the tread area is largerthan 6 mm (3/16 in). These punc-tures cannot be repaired ade-quately.



6-39

SIDE STAND/IGNITION INTERLOCK SYSTEM

Check the side stand/ignition inter-lock system for proper operation asfollows:1. Sit on the motorcycle in the nor-

mal riding position, with the sidestand up.

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

3. While continuing to hold the clutchin, move the side stand to thedown position.

If the engine stops running when theside stand is moved to the down posi-tion then the side stand/ignition inter-lock system is working properly. If theengine continues to run with the sidestand down and the transmission ingear, then the side stand/ignitioninterlock system is not working prop-erly. Have your motorcycle inspectedby an authorized Suzuki dealer or aqualified service mechanic.

WARNINGIf the side stand/ignition interlocksystem is not working properly, itis possible to ride the motorcyclewith the side stand in the downposition. This may interfere withrider control during a left turn andcould cause an accident.

Check the side stand/ignitioninterlock system for proper opera-tion before riding. Check that theside stand is returned to its full upposition before starting off.



6-40

FRONT WHEEL REMOVAL1. Place the motorcycle on the side

stand.

2. Remove both brake calipers fromthe front forks by removing twomounting bolts 1 on each of thecalipers.

NOTE: Never squeeze the front brakelever with the caliper removed. It isvery difficult to force the pads backinto the caliper assembly and brakefluid leakage may result.

3. Loosen the axle holder bolts 2.Loosen the axle 3 temporarily.

NOTE: A special tool is necessary toloosen the axle. The special tool isavailable from a Suzuki dealer.

4. Place an accessory service standor equivalent under the swingarmto help stabilize the rear end.Carefully position a jack under theengine or chassis tubes and raisethe jack until the front wheel isslightly off the ground.

5. Turn the axle counterclockwiseand draw it out.

NOTICEImproper jacking may cause dam-age to the oil filter.

Do not place the jack under the oilfilter when jacking up the motorcy-cle.



6-41

6. Slide the front wheel forward.

NOTE: Never squeeze the front brakelever with the front wheel removed. Itis very difficult to force brake padsinto the caliper assembly.

7. To reinstall the wheel assembly,reverse the sequence describedabove.

8. After installing the wheel, applythe front brake several times torestore the proper lever stroke.

Front axle tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft)

Front axle holder bolt tightening torque: 23 N·m (2.3 kgf-m, 16.5 lbf-ft)

Front brake caliper mounting bolt tightening torque: 39 N·m (3.9 kgf-m, 28.0 lbf-ft)

WARNINGFailure to extend brake pads afterinstalling the wheel can causepoor braking performance andmay result in an accident.

Before riding, “pump” the brakelever repeatedly until the brakepads are pressed against thebrake disks and proper leverstroke and firm feel are restored.Also check that the wheel rotatesfreely.

WARNINGInstalling the front wheel in thereverse direction can be hazard-ous. The tire for this motorcycle isdirectional. Therefore, the motor-cycle may have unusual handlingif the wheel is installed incorrectly.

Install the front wheel so that thetire rotates in the specified direc-tion, as indicated by the arrow onthe sidewall of the tire.

WARNINGIf the bolts and nuts are not prop-erly tightened, the wheel cancome off, causing an accident.

Be sure to tighten the bolts andnuts to the specified torque. If youdo not have a torque wrench or donot know how to use one, askyour authorized Suzuki dealer tocheck the bolts and nuts.



6-42

REAR WHEEL REMOVAL 1. Place the motorcycle on the sidestand.

2. Remove the bolt 1. Remove theaxle nut 2.

3. Place an accessory service standor equivalent under the swingarmor chassis tubes to stabilize therear end.

NOTICERemoving the rear wheel withoutuse of an accessory stand canresult in your motorcycle fallingover and being damaged.

Do not attempt roadside removalof the rear wheel. Only remove therear wheel at a properly equippedservicing facility using an acces-sory service stand.

CAUTIONA hot muffler can burn you.

Wait until the muffler cools beforeremoving the axle nut.



6-43

4. Draw out the axle.

5. Remove the wheel from thesplined drive gear and set thewheel assembly on the ground.

6. Remove the rear wheel assembly.7. To replace the wheel reverse the

complete sequence listed.

Rear axle tightening torque:110 N·m (11.0 kgf-m, 79.5 lbf-ft)

Rear brake caliper bracket mounting bolt tightening torque: 94 N·m (9.4 kgf-m, 68.0 lbf-ft)

NOTE: Apply a drop of SUZUKITHREAD LOCK “1322D” to the rearbrake mounting bolt.

WARNINGIf the bolts and nuts are not prop-erly tightened, the wheel cancome off, causing an accident.

Be sure to tighten the bolts andnuts to the specified torque. If youdo not have a torque wrench or donot know how to use one, askyour authorized Suzuki dealer tocheck the bolts and nuts.



6-44

LIGHT BULB REPLACEMENTThe wattage rating of each bulb isshown on the chart below. Whenreplacing a burned out bulb, alwaysuse the exact same wattage rating.Using other than the specified ratingcan result in overloading the electricalsystem or premature failure of a bulb.

* Canada, Middle East** Except for Canada and Middle East

HEADLIGHTTo replace the headlight bulb, followthe procedure below:

1. Remove the right and left bolts 1.

NOTICEFailure to use a light bulb with thecorrect wattage rating can over-load the electrical system of yourmotorcycle or cause the bulb toburn out sooner.

Use only the light bulbs shown inthe chart as replacement bulbs.

Headlight 12V 60/55W (H4)

Turn signal lightFront 12V 21W

* 12V 21/5W

Rear 12V 21W

**Position light 12V 5W



6-45

2. Unhook the hooks. Remove theheadlight assembly 2.

3. Disconnect the socket 3 from theheadlight and rubber cap 4.

4. Unhook the bulb holder spring 5,and you can pull out the bulb.

5. To replace the headlight bulb,reverse the above completesequence.

NOTICEThe headlight bulb’s life may beshortened by oil from your fingersif you touch it.

When replacing the headlightbulb, be careful not to touch theglass. Grasp the new bulb with aclean cloth.



6-46

POSITION LIGHT (Except for Canada and Middle East)

1. Pull out the position light socket.

2. Remove the position light bulb.

HEADLIGHT BEAM ADJUSTMENTThe headlight beam can be adjustedboth up and down or right and left ifnecessary.

To adjust the beam up and down:Insert 5 mm hexagon wrench asshown and turn the adjuster clock-wise or counterclockwise.

To adjust the beam right and left:Insert 5 mm hexagon wrench asshown and turn the adjuster clock-wise or counterclockwise.



6-47

TURN SIGNAL LIGHTTo replace the turn signal light bulb,follow the procedure below:

1. Remove the screw 1. 2. Turn the lens counterclockwise

and remove it.

3. Push in on the bulb 2, turn it tothe left and pull it out.

4. To fit the replacement bulb, push itin and turn it to the right whilepushing.

NOTICEOvertightening the screws whenreinstalling the lens may causethe lens to crack.

Tighten the screws only until theyare snug.



6-48

FUSESIf something electrical on your motor-cycle stops working, the first thing youshould check for is blown fuse. Theelectrical circuits on the motorcycleare protected from overload by fusesin the circuits.

If a blown fuse is found, then the elec-trical problem must be inspected andrepaired before replacing the blownfuse with a new fuse. Consult yourSuzuki dealer for the electrical systemcheck and repair.

MAIN FUSE

The main fuse is located under theseat. One 30A spare fuse is located inthe fuse box.

FUSES

The fuses are located under the seat.Two spare fuses (10A and one 15A)are provided in the fuse box.

WARNINGReplacing a fuse with incorrectamperage rating or substitute, e.g.aluminum foil or wire, may causeserious damage to the electricalsystem and possibly fire. Alwaysreplace a blown fuse with a fuse ofthe same amperage rating.

If the new fuse blows in a shorttime, the electrical problem maynot be fixed. Have your motorcy-cle inspected immediately by yourSuzuki dealer.

SPA

RE

10AHEAD HI

10AHEAD LO

15AIGNITION

15ASIGNAL

10AFUEL15AFAN

SPA

RE



6-49

FUSE LIST• 30A MAIN fuse protects all electri-

cal circuits.• 10A HEAD-HI fuse protects the

speedometer and headlight highbeam.

• 10A HEAD-LO fuse protects theheadlight low beam.

• 10A FUEL fuse protects the ECU,fuel pump, injectors and speed-ometer.

• 15A IGNITION fuse protects theheadlight relay, fan motor relay,*oxygen sensors, de-comp sole-noids, ECU, fuel pump relay,starter relay and ignition coils.

• 15A SIGNAL fuse protects thetachometer, horn, speedometer,turn signal light, license light,brake light, taillight and *positionlight.

• 15A FAN fuse protects the coolingfan motor.

* Except for Canada and Middle East

CATALYTIC CONVERTERThe purpose of the catalytic converteris to minimize the amount of harmfulpollutants in your motorcycle’sexhaust. Use of leaded fuel in motor-cycles equipped with catalytic con-verters is prohibited because leaddeactivates the pollutant-reducingcomponents of the catalyst system.

The converter is designed to last thelife of the motorcycle under normalusage and when unleaded fuel isused. Not special maintenance isrequired on the converter. However, itis very important to keep the engineproperly tuned. Engine misfiring,which can result from an improperlytuned engine, may cause overheat-ing of the catalyst. This may result inpermanent heat damage to the cata-lyst and other motorcycle compo-nents.



6-50

NOTICEImproper motorcycle operationcan cause catalyst or other motor-cycle damage.

To avoid damage to the catalyst orother related components, youshould take the following precau-tions:• Maintain the engine in the

proper operating condition.• In the event of an engine mal-

function, particularly one involv-ing engine misfire or otherapparent performance loss,stop riding the motorcycle andturn off the engine and have themotorcycle serviced promptly.

• Do not shut off the engine orinterrupt the ignition when thetransmission is in gear and themotorcycle is in motion.

• Do not try to start the engine bypushing the motorcycle or bycoasting down a hill.

• Do not idle the engine with anyspark plug wires disconnectedor removed, such as duringdiagnostic testing.

• Do not idle the vehicle for pro-longed periods if idling seemsrough or there are other mal-functions.

• Do not allow the fuel tank to getnear the empty level.

WARNINGIf you park or operate the motorcy-cle in areas where there are com-bustible materials such as drygrass or leaves, these materialsmay come in contact with the cat-alytic converter or other hotexhaust components. This cancause a fire.

Avoid parking or operating yourvehicle in areas with any combus-tible materials.



7-1

7

TROUBLESHOOTING

FUEL SUPPLY CHECK ....................................................................................... 7-2IGNITION SYSTEM CHECK ................................................................................ 7-3ENGINE STALLING ............................................................................................. 7-3



7-2

TROUBLESHOOTING

This troubleshooting guide is providedto help you find the cause of somecommon complaints.

If the engine refuses to start performthe following inspections to determinethe cause.

FUEL SUPPLY CHECKIf the fuel injection indicator displays“FI”, showing signs of trouble in thefuel injection system, take yourmachine to an authorized Suzukidealer. Refer to the “INSTRUMENTPANEL” section for an explanation offuel injection system indicator.NOTICE

Improper repairs or adjustmentsmay damage the motorcycleinstead of fixing it. Such damagemay not be covered under war-ranty.

If you are not sure about theproper action, consult your Suzukidealer about the problem.



7-3

IGNITION SYSTEM CHECK1. Remove two spark plugs and re-

attach them to the spark plugleads.

2. Hold the spark plug firmly againstthe engine and push the starterswitch with the ignition switch inthe “ON” position, the engine stopswitch in the “” position, thetransmission in neutral, and theclutch disengaged. If the ignitionsystem is operating properly, ablue spark should jump across thespark plug gap. If there is still nospark, take your motorcycle to anauthorized Suzuki dealer.

ENGINE STALLING1. Make sure there is enough fuel in

the fuel tank.2. If the fuel injection indicator dis-

plays “FI”, showing signs of trou-ble in the fuel injection system,take your machine to an autho-rized Suzuki dealer. Refer to the“INSTRUMENT PANEL” sectionfor an explanation of fuel injectionsystem indicator.

3. Check the ignition system forintermittent spark.

4. Check the idle speed. The correctidle speed is 800 – 1000 r/min.

WARNINGPerforming the spark test improp-erly can be hazardous. You couldget a high voltage electrical shockif you are not familiar with thisprocedure.

Do not perform this check if youare not familiar with the proce-dure. Do not point the spark plugnear the spark plug hole duringthis test. Do not perform this testif you have a heart condition orwear a pacemaker.



8-1

8


STORAGE PROCEDURE .................................................................................... 8-2PROCEDURE FOR RETURNING TO SERVICE ................................................. 8-3CORROSION PREVENTION ............................................................................... 8-3MOTORCYCLE CLEANING ................................................................................ 8-4INSPECTION AFTER CLEANING ....................................................................... 8-6



8-2


STORAGE PROCEDUREIf your motorcycle is to be left unusedfor an extended period of time, itneeds special servicing requiringappropriate materials, equipment andskill. For this reason, Suzuki recom-mends that you trust this mainte-nance work to your Suzuki dealer. Ifyou wish to service the machine forstorage yourself, follow the generalguidelines below:

MOTORCYCLEClean the entire motorcycle. Placethe motorcycle on the side stand on afirm, flat surface where it will not fallover.

FUEL1. Fill the fuel tank to the top with

fuel mixed with the amount of gas-oline stabilizer recommended bythe stabilizer manufacturer.

2. Run the engine for a few minutesuntil the stabilized gasoline fillsthe fuel injection system.

ENGINE1. Pour one tablespoon of motor oil

into each spark plug hole. Rein-stall the spark plugs and crank theengine a few times.

2. Drain the engine oil thoroughlyand refill the crankcase with freshengine oil all the way up to thefiller hole.

3. Cover the air cleaner intake andthe muffler outlet with oily rags toprevent humidity from entering.

BATTERY1. Remove the battery from the

motorcycle by referring to theBATTERY section.

2. Clean the outside of the batterywith a mild soap and remove cor-rosion from the terminals and wir-ing harness.

3. Store the battery in a room abovefreezing.

TIRESInflate tires to the normal pressure.

EXTERNAL• Spray all vinyl and rubber parts

with rubber protectant.• Spray unpainted surfaces with

rust preventative.• Coat painted surfaces with car

wax.

MAINTENANCE DURING STORAGEOnce a month, recharge the battery.The standard charging rate is 1.8A ×5 to 10 hours.



8-3

PROCEDURE FOR RETURNING TO SERVICE1. Clean the entire motorcycle.2. Remove the oily rags from the air

cleaner intake and muffler outlet.3. Drain all the engine oil. Install a

new oil filter and fill the enginewith fresh oil as outlined in thismanual.

4. Remove the spark plugs. Turn theengine a few times. Reinstall thespark plugs.

5. Reinstall the battery by referringto the BATTERY section.

6. Make sure that the motorcycle isproperly lubricated.

7. Perform the INSPECTIONBEFORE RIDING as listed in thismanual.

8. Start the motorcycle as outlined inthis manual.

CORROSION PREVENTIONIt is important to take good care ofyour motorcycle to protect it from cor-rosion and keep it looking new foryears to come.

Important Information About CorrosionCommon causes of corrosion• Accumulation of road salt, dirt,

moisture, or chemicals in hard-to-reach areas.

• Chipping, scratches, and anydamage to treated or paintedmetal surfaces resulting fromminor accidents or impacts fromstones and gravel.

Road salt, sea air, industrial pollution,and high humidity will all contribute tocorrosion.

How to Help Prevent Corrosion• Wash your motorcycle frequently,

at least once a month. Keep yourmotorcycle as clean and dry aspossible.

• Remove foreign material deposits.Foreign material such as roadsalt, chemicals, road oil or tar, treesap, bird droppings and industrialfall-out may damage your motor-cycle’s finish. Remove these typesof deposits as quickly as possible.If these deposits are difficult towash off, an additional cleanermay be required. Follow the man-ufacturer’s directions when usingthese special cleaners.



8-4

• Repair finish damage as soon aspossible. Carefully examine yourmotorcycle for damage to thepainted surfaces. Should you findany chips or scratches in thepaint, touch them up immediatelyto prevent corrosion from starting.If the chips or scratches havegone through to the bare metal,have a Suzuki dealer make therepair.

• Store your motorcycle in a dry,well-ventilated area. If you oftenwash your motorcycle in thegarage or if you frequently park itinside when wet, your garage maybe damp. The high humidity maycause or accelerate corrosion. Awet motorcycle may corrode evenin a heated garage if the ventila-tion is poor.

• Cover your motorcycle. Exposureto mid-day sun can cause the col-ors in paint, plastic parts, andinstrument faces to fade. Coveringyour motorcycle with a high-qual-ity, “breathable” motorcycle covercan help protect the finish fromthe harmful UV rays in sunlight,and can reduce the amount ofdust and air pollution reaching thesurface. Your Suzuki dealer canhelp you select the right cover foryour motorcycle.

MOTORCYCLE CLEANINGWASHING THE MOTORCYCLEWhen washing the motorcycle, followthe instructions below:1. Remove dirt and mud from the

motorcycle with cool runningwater. You may use a soft spongeor brush. Do not use hard materi-als which can scratch the paint.

2. Wash the entire motorcycle with amild detergent or car wash soapusing a sponge or soft cloth. Thesponge or cloth should be fre-quently soaked in the soap solu-tion.

NOTE: Clean the motorcycle immedi-ately after riding on road salt or ridingalong coast with cool water. Be sureto use cool water because warmwater can hasten corrosion.

NOTE: Avoid spraying or allowingwater to flow over the followingplaces:• Ignition switch• Spark plugs• Fuel tank cap• Throttle body• Fuel injection system• Brake master cylinders• Throttle cable boots



8-5

3. Once the dirt has been completelyremoved, rinse off the detergentwith running water.

4. After rinsing, wipe off the motorcy-cle with a wet chamois or clothand allow it to dry in the shade.

5. Check carefully for damage topainted surfaces. If there is anydamage, obtain “touch-up” paintand “touch-up” the damage follow-ing the procedure below:a.Clean all damaged spots and

allow them to dry.b. Stir the paint and “touch-up” the

damaged spots lightly with asmall brush.

c. Allow the paint to dry com-pletely.

NOTE: Headlight lens can be foggedafter washing the motorcycle or ridingin a rain. Headlight fogging will becleared gradually when the headlightis turned on. To clear the headlightlens fogging, run the engine to avoidbattery discharge.

NOTICEHigh pressure washers such asthose found at coin-operated carwashes have enough pressure todamage the parts of your motorcy-cle. It may cause rust, corrosionand increase wear. Parts cleanercan also damage motorcycleparts.

Do not use high pressure washersto clean your motorcycle. Do notuse parts cleaner on throttle bodyand fuel injection sensors.

NOTICECleaning your motorcycle with anyalkaline or strong acid cleaner,gasoline, brake fluid, or any othersolvent will damage the motorcy-cle parts.

Clean only with soft cloth andwarm water with mild detergent.



8-6

WAXING THE MOTORCYCLEAfter washing the motorcycle, waxingand polishing are recommended tofurther protect and beautify the paint.• Only use waxes and polishes of

good quality.• When using waxes and polishes,

observe the precautions specifiedby the manufacturers.

SPECIAL CARE FOR MATTE FINISH PAINTDo not use polishing compounds orwaxes that contain polishing com-pounds on surfaces which have amatte finish. The use of polishingcompounds will change the appear-ance of the matte finish.

Solid type waxes may be difficult toremove from surfaces with a mattefinish.

Friction while riding, excessive rub-bing or polishing of a surface with amatte finish will change its appear-ance.

INSPECTION AFTER CLEANINGFor extended life of your motorcycle,lubricate according to “LUBRICATIONPOINTS” section.

Follow the procedures in the“INSPECTION BEFORE RIDING”section to check your motorcycle forany problems that may have arisenduring your last ride.

WARNINGOperating the motorcycle with wetbrakes can be hazardous. Wetbrakes may not provide as muchstopping power as dry brakes.This could lead to an accident.

Test your brakes after washing themotorcycle, while riding at slowspeed. If necessary, apply thebrakes several times to let frictiondry out the linings.



SPECIFICATIONS

DIMENSIONS AND CURB MASSOverall length ..................................................2480 mm (97.6 in)

2450 mm (96.5 in) ... Canada, Middle EastOverall width.................................................... 875 mm (34.4 in)Overall height ..................................................1130 mm (44.5 in)Wheelbase ......................................................1710 mm (67.3 in)Ground clearance............................................ 130 mm (5.1 in)Seat height ...................................................... 705 mm (27.8 in)Curb mass ....................................................... 347 kg (764 lbs)

ENGINEType.................................................................Four-stroke, liquid-cooled, DOHC, 54-degree, V-twinNumber of cylinders ........................................2Bore.................................................................112.0 mm (4.409 in)Stroke ..............................................................90.5 mm (3.563 in)Displacement...................................................1783 cm3 (108.8 cu. in)Compression ratio ...........................................10.5 : 1Fuel system.....................................................Fuel injectionAir cleaner .......................................................Non-woven fabric elementStarter system .................................................ElectricLubrication system ..........................................Semi-Dry sump

DRIVE TRAINClutch ..............................................................Wet multi-plate typeTransmission ...................................................5-speed constant meshGearshift pattern .............................................1-down, 4-upPrimary reduction ratio ....................................1.647 (56/34)

1.757 (58/33) ... Canada, Middle EastGear ratios, Low ..............................................2.187 (35/16)

2nd...............................................1.400 (28/20)3rd ...............................................1.038 (27/26)4rd ...............................................0.827 (24/29)Top...............................................0.685 (24/35)

Final reduction ratio.........................................2.823 (18/17 × 32/12)Drive system....................................................Shaft drive

CHASSISFront suspension .............................................Inverted telescopic, coil spring, oil dampedRear suspension .............................................Link type, coil spring, oil dampedFront fork stroke ..............................................130 mm (5.1 in)Rear wheel travel.............................................118 mm (4.6 in)Caster..............................................................31° 15’Trail ..................................................................124 mm (4.88 in)Steering angle .................................................37° (right & left)Turning radius..................................................3.3 m (10.8 ft)Front brake ......................................................Disk brake, twinRear brake.......................................................Disk brakeFront tire size...................................................130/70R18M/C 63V, tubelessRear tire size ...................................................240/40R18M/C 79V, tubeless



ELECTRICALIgnition type .....................................................Electronic ignition (Transistorized)Spark plug .......................................................NGK CR8EK or DENSO U24ETRBattery.............................................................12V 64.8kC (18Ah)/10HRGenerator ........................................................Three-phase A.C. GeneratorMain fuse.........................................................30AFuse ................................................................10/10/10/15/15/15AHeadlight .........................................................12V 60/55W (H4)Position light ....................................................12V 5W ... Except for Canada and Middle EastBrake light/Taillight...........................................LEDFront turn signal light .......................................12V 21W

12V 21/5W ... Canada, Middle EastRear turn signal light .......................................12V 21WLicense plate light............................................12V 5WSpeedometer light ...........................................LEDHigh beam indicator light.................................LEDTurn signal indicator light.................................LEDNeutral indicator light.......................................LEDCoolant temperature/Oil pressure indicator light...............................LEDFuel level indicator light ...................................LEDFuel injection indicator light .............................LEDTachometer light ..............................................LED

CAPACITIESFuel tank.......................................................... 19.5 L (5.2/4.3 US/lmp. gal)Engine oil, without filter change .....................3400 ml (3.6/3.0 US/lmp. qt)

With filter change..........................3600 ml (3.8/3.2 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

AACCESSORY USE AND MOTORCYCLE LOADING .............. 1-2AIR CLEANER............................... 6-10ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING....... 4-3AVOID CONSTANT LOW SPEED............................................. 4-2

BBATTERY ........................................ 6-8BRAKES ........................................ 6-30BREAKING IN THE NEW TIRE....... 4-2

CCATALYTIC CONVERTER ........... 6-49CLUTCH ADJUSTMENT............... 6-25COOLANT .............................. 3-5,6-26CORROSION PREVENTION .......... 8-3

EENGINE IDLE SPEED INSPECTION................................. 6-24ENGINE OIL ........................... 3-4,6-18ENGINE STALLING......................... 7-3

FFINAL GEAR OIL.................... 3-5,6-29FRONT WHEEL REMOVAL.......... 6-40FUEL HOSE .................................. 6-25FUEL OCTANE RATING................. 3-2FUEL SUPPLY CHECK................... 7-2FUEL TANK CAP........................... 2-18FUSES........................................... 6-48

GGEARSHIFT LEVER ..................... 2-19

HHELMET HOLDER ........................ 2-21

IIGNITION SWITCH.......................... 2-5IGNITION SYSTEM CHECK ........... 7-3INSPECTION AFTER CLEANING ...................................... 8-6INSPECTION BEFORE RIDING ..... 4-3INSTRUMENT PANEL .................... 2-7

KKEY.................................................. 2-5

LLABELS ........................................... 1-5LEFT HANDLEBAR....................... 2-13LIGHT BULB REPLACEMENT...... 6-44LOCATION OF PARTS ................... 2-2LUBRICATION POINTS .................. 6-7

MMAINTENANCE SCHEDULE.......... 6-2MAXIMUM ENGINE SPEED RECOMMENDATION...................... 4-2MODIFICATION............................... 1-4MOTORCYCLE CLEANING............ 8-4



NNOISE CONTROL SYSTEM (AUSTRALIA ONLY)........................ 1-6

OOBSERVE YOUR FIRST AND MOST CRITICAL SERVICE ............ 4-3OXYGENATED FUEL RECOMMENDATION...................... 3-2

PPROCEDURE FOR RETURNING TO SERVICE......................................... 8-3

RREAR BRAKE PEDAL................... 2-19REAR WHEEL REMOVAL ............ 6-42RIDING ON HILLS........................... 5-5RIGHT HANDLEBAR..................... 2-16

SSAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ........ 1-4SEAT LOCK................................... 2-20SEAT TAIL COVER....................... 2-24SERIAL NUMBER LOCATION........ 1-6SIDE STAND ................................. 2-21SIDE STAND/IGNITION INTERLOCK SYSTEM .................. 6-39SPARK PLUGS ............................. 6-13STARTING OFF .............................. 5-3STARTING THE ENGINE................ 5-2STEERING LOCK............................ 2-6STOPPING AND PARKING ............ 5-5STORAGE PROCEDURE ............... 8-2SUSPENSION ADJUSTMENT...... 2-22

TTHROTTLE CABLE ADJUSTMENT............................... 6-23TIRES ............................................ 6-35TOOLS............................................. 6-7

UUSING THE TRANSMISSION......... 5-4

VVARY THE ENGINE SPEED........... 4-2

Total page: 116



99011-48G59-01A

VZ

R1800/B

Z

Part No. 99011-48G59-01A September, 2014 EN© COPYRIGHT SUZUKI MOTOR CORPORATION 2014 Printed in Japan

VZR1800/BZOWNER’S MANUAL

TK L5

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