Name: Suzuki VLR1800
Brand: Suzuki
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Brake Control System and Diagnosis: 4A-13

Rear Brake Master Cylinder Components

B822H14106015

FWD

(b)

(c)

(a)

I822H1410056-01

1. Reservoir tank 4. Master cylinder : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply silicone grease.

2. Brake hose union bolt 5. Piston/Cup set : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply brake fluid.

3. Brake hose connector 6. Push rod : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) : Do not reuse.

Table of Contents65
Precautions69
Precautions for Engine69
Engine General Information and Diagnosis70
General Description70
Injection Timing Description70
Self-Diagnosis Function71
Schematic and Routing Diagram73
FI System Wiring Diagram73
Terminal Alignment of ECM Coupler74
Component Location75
FI System Parts Location75
Diagnostic Information and Procedures77
Engine Symptom Diagnosis77
Self-Diagnostic Procedures81
Use of SDS Diagnosis Reset Procedures83
Show Data When Trouble (Displaying Data at the Time of DTC)84
SDS Check86
DTC Table89
Fail-Safe Function Table91
FI System Troubleshooting92
Malfunction Code and Defective Condition Table93
DTC "C12" (P0335): CKP Sensor Circuit Malfunction96
DTC "C13" (P1750-H/L) or "C17" (P0105-H/L): IAP Sensor Circuit Malfunction99
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction107
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction116
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction121
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction126
DTC "C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354): Ignition System Malfunction133
DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction133
DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction137
DTC "C31" (P0705): GP Switch Circuit Malfunction144
DTC "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction146
DTC "C40" (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction149
DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction153
DTC "C42" (P1650): IG Switch Circuit Malfunction155
DTC "C44" (P0156) or "C64" (P0130): O2 Sensor (O2S) Circuit Malfunction (for156
DTC "C46" (P1657-H/L or P1658): EXCV Actuator Circuit Malfunction160
DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction173
DTC "C61" (P1656): PAIR Control Solenoid Valve Circuit Malfunction176
DTC "C62" (P0443): EVAP System Purge Control Solenoid Valve Circuit Malfunction (for179
Specifications183
Service Data183
Special Tools and Equipment184
Special Tool184
Emission Control Devices186
Precautions186
Precautions for Emission Control Devices186
General Description186
Fuel Injection System Description186
Crankcase Emission Control System Description187
Exhaust Emission Control System Description188
Noise Emission Control System Description189
Evaporative Emission Control System190
Schematic and Routing Diagram191
PAIR System Hose Routing Diagram191
EVAP Canister Hose Routing Diagram193
Repair Instructions194
Oxygen Sensor (O2S) Removal and Installation194
Heated Oxygen Sensor (O2S) Inspection195
PAIR Reed Valve Removal and Installation195
PAIR Control Solenoid Valve Removal and Installation195
PAIR System Inspection196
Crankcase Breather (PCV) Hose Inspection197
Crankcase Breather (PCV) Hose Cover Removal and Installation197
Crankcase Breather (PCV) Cover Inspection198
Evaporative Emission Control System198
Removal and Installation (Only for198
Evaporative Emission Control System Inspection (for E-33 Only)199
Specifications201
Service Data201
Tightening Torque Specifications201
Special Tools and Equipment201
Recommended Service Material201
Special Tool201
Engine Electrical Devices202
Precautions202
Precautions for Engine Electrical Device202
Component Location202
Engine Electrical Components Location202
Diagnostic Information and Procedures202
Engine Symptom Diagnosis202
Repair Instructions202
ECM Removal and Installation202
CKP Sensor Inspection202
IAP Sensor Removal and Installation203
TP Sensor Inspection203
TP Sensor Removal and Installation203
TP Sensor Adjustment203
IAT Sensor Removal and Installation204
ECT Sensor Removal and Installation204
ECT Sensor Inspection205
TO Sensor Removal and Installation206
TO Sensor Inspection206
STP Sensor Inspection206
STP Sensor Adjustment206
STP Sensor Removal and Installation207
STV Actuator Inspection208
STV Actuator Removal and Installation208
ISC Valve Inspection208
ISC Valve Removal and Installation208
ISC Valve Preset and Opening Initialization208
O2 Sensor Inspection209
O2 Sensor Removal and Installation209
GP Switch Inspection209
GP Switch Removal and Installation209
Specifications210
Service Data210
Tightening Torque Specifications210
Special Tools and Equipment211
Recommended Service Material211
Special Tool211
Engine Mechanical212
Schematic and Routing Diagram212
Camshaft and Sprocket Assembly Diagram212
Throttle Cable Routing Diagram213
Diagnostic Information and Procedures214
Engine Mechanical Symptom Diagnosis214
Compression Pressure Check214
Repair Instructions215
Engine Components Removable with the Engine in Place215
Air Cleaner Element Removal and Installation217
Air Cleaner Element Inspection and Cleaning217
Air Cleaner Chamber Removal and Installation217
Throttle Body Components219
Throttle Body Construction220
ISC Valve Removal and Installation221
Throttle Body Removal and Installation221
Throttle Body Disassembly and Assembly223
Throttle Body Inspection and Cleaning226
Throttle Valve Synchronization227
ISC Valve Reset229
Engine Assembly Removal229
Engine Assembly Installation234
Engine Top Side Disassembly236
Engine Top Side Assembly241
Valve Clearance Inspection and Adjustment254
Cylinder Head Cover Inspection254
Camshaft Inspection254
Camshaft Sprocket and Automatic-Decomp. Inspection256
Cam Chain Tension No. 1 and No. 2 Adjuster Inspection256
Cam Chain Guide No. 1, No. 2 and No. 3257
Inspection257
Cam Chain Tensioner No. 1 Inspection257
Cylinder Head Cover Disassembly and Assembly257
PAIR Reed Valve / PAIR Reed Valve Cover Inspection258
Cylinder Head Disassembly and Assembly258
Cylinder Head Related Parts Inspection262
Valve Guide Replacement264
Valve Seat Repair265
Cam Chain Tensioner No. 2 Inspection266
Cylinder Inspection266
Piston Ring Removal and Installation267
Piston and Piston Ring Inspection268
Engine Bottom Side Disassembly270
Engine Bottom Side Assembly279
Conrod Removal and Installation295
Conrod / Crankshaft Inspection297
Conrod Crank Pin Bearing Inspection and Selection297
Crankshaft Journal Bearing Inspection and Selection299
Crankshaft Thrust Clearance Inspection and Selection301
Balancer Driven Gear Disassembly and Assembly303
Balancer Shaft Parts Inspection305
Specifications306
Service Data306
Tightening Torque Specifications308
Special Tools and Equipment309
Recommended Service Material309
Special Tool310
Engine Lubrication System313
Precautions313
Precautions for Engine Oil313
Schematic and Routing Diagram313
Engine Lubrication System Chart Diagram313
Diagnostic Information and Procedures314
Engine Lubrication Symptom Diagnosis314
Oil Pressure Check314
Repair Instructions315
Engine Oil and Filter Replacement315
Engine Oil Level Inspection315
Oil Pan / Oil Strainer / Oil Pressure Regulator315
Removal and Installation315
Oil Pressure Regulator / Oil Strainer Inspection317
Oil Cooler Removal and Installation318
Oil Pressure Switch Removal and Installation319
Oil Pressure Switch Inspection319
Oil Jet Removal and Installation319
Oil Jet / Oil Gallery Jet Inspection321
Oil Pump Removal and Installation321
Oil Pump Inspection322
Specifications323
Service Data323
Tightening Torque Specifications323
Special Tools and Equipment324
Recommended Service Material324
Special Tool324
Engine Cooling System325
Precautions325
Precautions for Engine Cooling System325
Precautions for Engine Coolant325
General Description325
Schematic and Routing Diagram326
Cooling Circuit Diagram326
Water Hose Routing Diagram327
Diagnostic Information and Procedures328
Engine Cooling Symptom Diagnosis328
Repair Instructions328
Cooling Circuit Inspection328
Radiator Cap Inspection329
Radiator Inspection and Cleaning329
Radiator / Cooling Fan Motor Removal and Installation329
Water Hose Inspection330
Water Hose Removal and Installation331
Radiator Reservoir Tank Inspection331
Radiator Reservoir Tank Removal and Installation332
Cooling Fan Inspection332
Cooling Fan Relay Inspection333
ECT Sensor Removal and Installation333
ECT Sensor Inspection333
Thermostat Removal and Installation333
Thermostat Inspection334
Water Pump Components335
Water Pump Removal and Installation336
Water Pump Disassembly and Assembly337
Water Pump Related Parts Inspection340
Specifications341
Service Data341
Tightening Torque Specifications341
Special Tools and Equipment342
Recommended Service Material342
Special Tool342
Fuel System343
Precautions343
Precautions for Fuel System343
General Description344
Fuel System Description344
Diagnostic Information and Procedures345
Fuel System Diagnosis345
Repair Instructions346
Fuel Pressure Inspection346
Fuel Pump Inspection346
Fuel Discharge Amount Inspection347
Fuel Pump Relay Inspection348
Fuel Hose Inspection348
Fuel Level Gauge Inspection348
Fuel Level Indicator Inspection348
Fuel Level Indicator Switch (Thermistor) Inspection348
Fuel Tank Construction349
Fuel Tank Removal and Installation350
Fuel Pump Components351
Fuel Pump Assembly / Fuel Level Gauge Removal and Installation352
Fuel Pump Disassembly and Assembly353
Fuel Mesh Filter Inspection and Cleaning354
Fuel Injector / Fuel Delivery Pipe Removal and Installation355
Fuel Injector Inspection and Cleaning355
Specifications355
Service Data355
Tightening Torque Specifications355
Special Tools and Equipment356
Recommended Service Material356
Special Tool356
Ignition System357
Schematic and Routing Diagram357
Ignition System Diagram357
Ignition System Components Location357
Diagnostic Information and Procedures358
Ignition System Symptom Diagnosis358
No Spark or Poor Spark359
Repair Instructions360
Ignition Coil / Plug Cap and Spark Plug Cap360
Removal and Installation360
Ignition Coil Removal and Installation361
Spark Plug Removal and Installation362
Spark Plug Inspection and Cleaning362
Ignition Coil / Plug Cap / Ignition Coil Inspection362
CKP Sensor Inspection365
CKP Sensor Removal and Installation366
Engine Stop Switch Inspection366
Ignition Switch Inspection366
Ignition Switch Removal and Installation366
Specifications367
Service Data367
Tightening Torque Specifications367
Special Tools and Equipment367
Special Tool367
Starting System368
Schematic and Routing Diagram368
Starting System Diagram368
Component Location368
Starting System Components Location368
Diagnostic Information and Procedures368
Starting System Symptom Diagnosis368
Starter Motor will Not Run369
Starter Motor Runs but Does Not Crank the Engine369
Repair Instructions370
Starter Motor Components370
Starter Motor Removal and Installation371
Starter Motor Disassembly and Assembly372
Starter Motor Inspection373
Starter Relay Removal and Installation374
Starter Relay Inspection374
Turn Signal / Side-Stand Relay Removal and Installation375
Side-Stand / Ignition Interlock System Parts Inspection375
Starter Torque Limiter / Starter Clutch Removal and Installation378
Starter Torque Limiter Inspection379
Starter Clutch Inspection380
Starter Button Inspection380
Specifications381
Service Data381
Tightening Torque Specifications381
Special Tools and Equipment382
Recommended Service Material382
Special Tool382
Charging System383
Schematic and Routing Diagram383
Charging System Diagram383
Component Location383
Charging System Components Location383
Diagnostic Information and Procedures383
Charging System Symptom Diagnosis383
Battery Runs down Quickly384
Repair Instructions385
Battery Current Leakage Inspection385
Regulated Voltage Inspection385
Generator Inspection386
Generator Removal and Installation387
Regulator / Rectifier Inspection389
Battery Components390
Battery Charging390
Battery / Battery Holder Removal and Installation392
Battery Visual Inspection394
Specifications395
Service Data395
Tightening Torque Specifications395
Special Tools and Equipment395
Recommended Service Material395
Special Tool395
Exhaust System396
Precautions396
Precautions for Exhaust System396
General Description396
Exhaust Control System Description396
Exhaust Control System Operation396
Repair Instructions397
Exhaust Control System Construction397
Exhaust System Components398
EXCVA / EXCV Cable Removal and Installation399
EXCVA Inspection402
EXCVA Pulley / EXCV Cable Inspection402
EXCVA Adjustment402
Exhaust Pipe / Muffler Removal and Installation404
Exhaust System Inspection407
EXCV Inspection407
Specifications408
Service Data408
Tightening Torque Specifications408
Special Tools and Equipment408
Recommended Service Material408
Special Tool408
Precautions410
Precautions for Suspension410
Suspension General Diagnosis411
Diagnostic Information and Procedures411
Suspension and Wheel Symptom Diagnosis411
Front Suspension412
Repair Instructions412
Front Fork Components412
Front Fork Removal and Installation413
Front Fork Disassembly and Assembly414
Front Fork Inspection414
Front Fork Parts Inspection419
Specifications420
Service Data420
Tightening Torque Specifications420
Special Tools and Equipment421
Recommended Service Material421
Special Tool421
Rear Suspension422
Repair Instructions422
Rear Suspension Components422
Rear Suspension Assembly Construction423
Rear Shock Absorber Removal and Installation424
Rear Suspension Inspection424
Rear Shock Absorber Inspection425
Rear Suspension Adjustment425
Rear Shock Absorber Disposal425
Swingarm / Cushion Lever Removal and Installation426
Cushion Lever / Cushion Rod Inspection428
Cushion Lever / Cushion Rod Bearing Removal and Installation429
Swingarm Related Parts Inspection431
Swingarm Bearing Removal and Installation432
Specifications433
Service Data433
Tightening Torque Specifications433
Special Tools and Equipment434
Recommended Service Material434
Special Tool434
Wheels and Tires435
Precautions435
Precautions for Wheel and Tire435
Repair Instructions436
Front Wheel Components436
Front Wheel Assembly Construction437
Front Wheel Assembly Removal and Installation438
Front Wheel Related Parts Inspection440
Front Wheel Dust Seal / Bearing Removal and Installation441
Rear Wheel Components443
Rear Wheel Assembly Construction444
Rear Wheel Assembly Removal and Installation445
Rear Wheel Related Parts Inspection446
Rear Wheel Dust Seal / Bearing Removal and Installation448
Tire Removal and Installation449
Wheel / Tire / Air Valve Inspection and Cleaning451
Air Valve Removal and Installation451
Wheel Balance Check and Adjustment452
Specifications453
Service Data453
Tightening Torque Specifications453
Special Tools and Equipment454
Recommended Service Material454
Special Tool454
Precautions458
Precautions for Driveline / Axle458
Drive Chain / Drive Train / Drive Shaft459
Diagnostic Information and Procedures459
Drive Chain and Sprocket Symptom Diagnosis459
Repair Instructions460
Secondary Gear Components460
Secondary Gear Construction461
Secondary Driven Gear Assembly Removal and Installation461
Secondary Driven Gear Disassembly and Assembly462
Secondary Driven Gear Related Parts Inspection467
Secondary Gear Shim Inspection and Adjustment468
Final Bevel Gear Components470
Final Gear Construction471
Final Gear Assembly Removal and Installation471
Final Gear Disassembly and Assembly472
Final Gear Parts Inspection479
Universal Joint Removal and Installation480
Universal Joint Inspection481
Rear Wheel Dumper Removal and Installation481
Wheel Dumper Inspection482
Final Gear Shim Inspection and Adjustment482
Specifications486
Service Data486
Tightening Torque Specifications486
Special Tools and Equipment487
Recommended Service Material487
Special Tool487
Precautions492
Precautions for Brake System492
Brake Fluid Information492
Brake Control System and Diagnosis493
Schematic and Routing Diagram493
Front Brake Hose Routing Diagram493
Rear Brake Hose Routing Diagram494
Diagnostic Information and Procedures495
Brake Symptom Diagnosis495
Repair Instructions496
Brake Pedal Height Inspection and Adjustment496
Front Brake Light Switch Inspection496
Rear Brake Light Switch Inspection496
Rear Brake Light Switch Inspection and Adjustment496
Brake Fluid Level Check497
Brake Hose Inspection497
Air Bleeding from Brake Fluid Circuit497
Brake Fluid Replacement498
Front Brake Hose Removal and Installation500
Rear Brake Hose Removal and Installation500
Front Brake Master Cylinder Components501
Front Brake Master Cylinder Assembly Removal and Installation502
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly503
Front Brake Master Cylinder Parts Inspection504
Rear Brake Master Cylinder Components505
Rear Brake Master Cylinder Removal and Installation506
Rear Brake Master Cylinder Disassembly and Assembly508
Rear Brake Master Cylinder Parts Inspection509
Service Data510
Tightening Torque Specifications510
Special Tools and Equipment511
Recommended Service Material511
Special Tool511
Front Brakes512
Repair Instructions512
Front Brake Components512
Front Brake Pad Inspection513
Front Brake Pad Replacement513
Front Brake Caliper Removal and Installation514
Front Brake Caliper Disassembly and Assembly515
Front Brake Caliper Parts Inspection518
Front Brake Disc Removal and Installation519
Front Brake Disc Inspection519
Service Data520
Tightening Torque Specifications520
Special Tools and Equipment521
Recommended Service Material521
Special Tool521
Rear Brakes522
Repair Instructions522
Rear Brake Components522
Rear Brake Pad Inspection523
Rear Brake Pad Replacement523
Rear Brake Caliper Removal and Installation524
Rear Brake Caliper Disassembly and Assembly525
Rear Brake Caliper Parts Inspection526
Rear Brake Disc Removal and Installation528
Rear Brake Disc Inspection528
Specifications529
Service Data529
Tightening Torque Specifications529
Special Tools and Equipment530
Recommended Service Material530
Special Tool530
Precautions532
Precautions for Transmission / Transaxle532
Manual Transmission533
Diagnostic Information and Procedures533
Manual Transmission Symptom Diagnosis533
Repair Instructions534
Transmission Components534
Transmission Removal535
Transmission Installation536
Transmission Construction539
Countershaft Gear / Driveshaft Gear Disassembly and Assembly540
Transmission Related Parts Inspection543
Gear Position (GP) Switch Inspection544
Gear Position (GP) Switch Removal and Installation544
Gearshift Lever Construction545
Gearshift Lever Removal and Installation546
Gearshift Lever Height Inspection and Adjustment546
Gearshift Shaft / Gearshift Cam Plate Components547
Gearshift Shaft / Gearshift Cam Plate Removal and Installation547
Gearshift Linkage Inspection550
Gearshift Shaft Oil Seal / Bearing Removal and Installation551
Specifications552
Service Data552
Tightening Torque Specifications552
Special Tools and Equipment553
Recommended Service Material553
Special Tool553
Clutch554
Precautions554
Precautions for Clutch System554
Schematic and Routing Diagram554
Clutch Cable Routing Diagram554
Diagnostic Information and Procedures554
Clutch System Symptom Diagnosis554
Repair Instructions555
Clutch Lever Position Switch Inspection555
Clutch Cable Removal and Installation555
Clutch Components556
Clutch Removal557
Clutch Installation559
Primary Driven Gear Removal and Installation562
Clutch Parts Inspection563
Specifications565
Service Data565
Tightening Torque Specifications565
Special Tools and Equipment566
Recommended Service Material566
Special Tool566
Precautions568
Precautions for Steering568
Steering General Diagnosis569
Diagnostic Information and Procedures569
Steering Symptom Diagnosis569
Steering / Handlebar570
Repair Instructions570
Handlebars Components570
Handlebars Removal and Installation571
Handlebars Inspection573
Steering Components573
Steering Removal and Installation574
Steering Related Parts Inspection576
Steering System Inspection577
Steering Stem Bearing Removal and Installation577
Steering Tension Adjustment578
Specifications578
Tightening Torque Specifications578
Special Tools and Equipment579
Recommended Service Material579
Special Tool579
Precautions583
Precautions for Electrical System583
Component Location583
Electrical Components Location583
Wiring Systems584
Schematic and Routing Diagram584
Wiring Diagram584
Wiring Harness Routing Diagram590
Specifications592
Service Data592
Lighting Systems593
Repair Instructions593
Headlight Components593
Headlight Removal and Installation594
Headlight Bulb Replacement594
Headlight Beam Adjustment595
Headlight Relay Inspection595
Rear Combination Light Components596
Rear Combination Light Removal and Installation596
License Plate Light Components597
License Plate Light Removal and Installation597
License Plate Light Bulb Replacement598
Turn Signal Light Components598
Front Turn Signal Light Removal and Installation599
Rear Turn Signal Light Removal and Installation599
Turn Signal Light Bulb Replacement600
Turn Signal / Side-Stand Relay Inspection600
Turn Signal / Side-Stand Relay Removal and Installation600
Hazard Switch Inspection600
Turn Signal Switch Inspection601
Passing Light Switch Inspection601
Dimmer Switch Inspection602
Specifications602
Service Data602
Special Tools and Equipment602
Special Tool602
Combination Meter / Fuel Meter / Horn603
General Description603
Combination Meter System Description603
Repair Instructions604
Combination Meter Components604
Combination Meter Removal and Installation604
Combination Meter Disassembly and Assembly604
Combination Meter Inspection605
Engine Coolant Temperature Indicator Light Inspection606
Engine Coolant Temperature Removal and Installation606
Fuel Level Indicator Inspection606
Fuel Level Indicator Switch (Thermistor) Inspection607
Fuel Level Gauge Inspection608
Speedometer Inspection608
Speed Sensor Removal and Installation608
Speed Sensor Inspection609
Oil Pressure Indicator Inspection610
Oil Pressure Switch Removal and Installation610
Ignition Switch Inspection610
Ignition Switch Removal and Installation610
Horn Inspection611
Horn Removal and Installation611
Specifications612
Service Data612
Tightening Torque Specifications612
Special Tools and Equipment612
Recommended Service Material612
Special Tool612
Exterior Parts613
Exterior Parts Construction613
Fastener Removal and Installation614
Exterior Parts Removal and Installation615
Specifications618
Tightening Torque Specifications618
Special Tools and Equipment618
Recommended Service Material618
Body Structure619
Repair Instructions619
Body Frame Construction619
Steering Lock Bracket Construction620
Front Footrest Bracket Construction620
Side-Stand Construction621
Side-Stand Removal and Installation621
Specifications622
Tightening Torque Specifications622
Special Tools and Equipment622
Recommended Service Material622

Brand	Suzuki
Model	VLR1800
Category	Motorcycle
Language	English

Suzuki VLR1800 Service Manual

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Suzuki VLR1800 Specifications

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