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VZR1800 2007
Suzuki VZR1800 2007 User Manual
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9-62
C
HAS
SIS
REAR BR
AKE
CON
STRUCTIO
N
1
P
isto
n/C
up set
7
Dust seal
#
2
Reservoir h
ose
8
Brake pad
spr
ing
ITE
M
N
·m
kgf
-m
lb
-ft
3
B
rake hose
A
Cali
pe
r air ble
eder valve
A
7
.5
0.75
5
.5
4
B
rake pad
B
Brake hos
e
union
bolt
B
23
2.3
1
6.5
5
Pi
st
on
C
Brake maste
r
cylinde
r rod
lock nut
C
1
8
1.8
13.0
6
P
ist
o
n seal
418
420
Table of Contents
General Information 1
12
Table of Contents
12
Warning/Caution/Note
13
General Precautions
13
Suzuki Vzr1800K6 ('06-Model)
15
Serial Number Location
15
Fuel, Oil and Engine Coolant Recommendation
16
Fuel (for Usa and Canada)
16
Fuel (for Other Countries)
16
Engine Oil (for Usa)
16
Engine Oil (for Other Countries)
16
Gear Oil (Final Drive Gear Oil)
16
Brake Fluid
16
Front Fork Oil
17
Engine Coolant
17
Break-In Procedures
18
Cylinder Identification
18
Information Labels
19
Specifications
20
Dimensions and Dry Mass
20
Engine
20
Drive Train
20
Chassis
21
Electrical
21
Capacities
21
Periodic Maintenance
22
Periodic Maintenance Schedule
23
Periodic Maintenance Chart
23
Lubrication Points
24
Maintenance and Tune-Up Procedures
25
Air Cleaner
25
Exhaust Pipe Bolts and Muffler Bolts
27
Exhaust Control Valve
28
Valve Clearance
29
Spark Plug
34
Fuel Line
37
Evaporative Emission Control System (E-33 Only)
37
Engine Oil and Oil Filter
38
Final Gear Oil
40
Throttle Cable Play
40
Pair (Air Supply) System
40
Throttle Valve Synchronization
41
Cooling System
41
Clutch Cable Play
43
Brake
44
Tires
48
Steering
49
Front Fork
49
Rear Suspension
50
Chassis Bolts and Nuts
50
Compression Pressure Check
52
Compression Test Procedure
52
Oil Pressure Check
53
Sds Check
54
Engine
58
Engine Removal and Installation
60
Engine Removal
60
Engine Installation
66
Engine Disassembly
70
Engine Components Inspection and Service
86
Cylinder Head Cover
86
Camshaft
86
Cam Chain Tension Adjuster
89
Cam Chain Tensioner
89
Cam Chain Guide
89
Cylinder Head and Valve
89
Cylinder
98
Piston and Piston Ring
99
Clutch
101
Gearshift Cover
103
Starter Clutch
104
Oil Pump
105
Starter Torque Limiter
107
Generator Cover
107
Clutch Release Camshaft
108
Water Pump
109
Gearshift
109
Oil Pressure Regulator
110
Oil Strainer
110
Transmission
111
Crankcase
117
Balancer Driven Gear
124
Crankshaft and Conrod
126
Crankshaft Journal Bearing
130
Crankshaft Thrust Bearing
133
Engine Reassembly
135
Driveline/Axle
172
Secondary Bevel Gears
173
Construction
173
Removal
175
Disassembly
175
Inspection
177
Reassembly
179
Secondary Gear Shims Adjustment
181
Final Bevel Gears
184
Construction
184
Final Gear Case Removal
186
Final Gear Case Disassembly
186
Final Gear Shims Adjustment
191
Final Gear Case Reassembly
195
Final Gear Case Installation
199
Fi System Diagnosis
202
Precautions in Servicing
204
Electrical Parts
204
Fuse
205
Ecm/Various Sensors
205
Electrical Circuit Inspection Procedure
207
Using the Multi-Circuit Tester
210
Fi System Technical Features
211
Injection Time (Injection Volume)
211
Compensation of Injection Time (Volume)
212
Injection Stop Control
212
Fi System Parts Location
213
Fi System Wiring Diagram
215
Ecm Terminal
216
Self-Diagnosis Function
218
User Mode
218
Dealer Mode
219
Tps Adjustment
221
Fail-Safe Function
222
Fi System Troubleshooting
223
Customer Complaint Analysis
223
Visual Inspection
224
Self-Diagnostic Procedures
225
Self-Diagnosis Reset Procedure
225
Use of Sds Diagnostic Procedures
226
Use of Sds Diagnosis Reset Procedure
227
Show Data When Trouble (Displaing Data at the Time of Dtc)
228
Malfunction Code and Defective Condition
229
C12" (P0335) Ckp Sensor Circuit Malfunction
233
C13" (P1750-H/L) or "C17" (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
235
C14" (P0120-H/L) Tp Sensor Circuit Malfunction
242
C15" (P0115-H/L) Ect Sensor Circuit Malfunction
247
C21" (P0110-H/L) Iat Sensor Circuit Malfunction
251
C23" (P1651-H/L) to Sensor Circuit Malfunction
255
C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354) IGNITION SYSTEM MALFUNCTION
258
C28" (P1655) Stv Actuator Circuit Malfunction
259
C29" (P1654-H/L) Stp Sensor Circuit Malfunction
262
C31" (P0705) Gp Switch Circuit Malfunction
267
C32" (P0201) or "C33" (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
269
C40" (P0505-H/L or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION
271
C41" (P0230-H/L) Fp Relay Circuit Malfunction
277
C42" (P01650) Ig Switch Circuit Malfunction
279
C44" (P0156/P0161) or "C64" (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION (for E-02, 19, 24)
280
C46" (P1657-H/L or P1658) EXCV ACTUATOR CIRCUIT MALFUNCTION
284
C49" (P1768) or "C61" (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
293
C60" (P0480) Cooling Fan Relay Circuit Malfunction
295
Sensors
298
Iap Sensor Inspection
298
Iap Sensor Removal and Installation
298
Tp Sensor Inspection
298
Tp Sensor Removal and Installation
298
Tps Adjustment
298
Stp Sensor Inspection
299
Stp Sensor Removal and Installation
299
Stp Sensor Adjustment
299
Ckp Sensor Inspection
299
Ckp Sensor Removal and Installation
299
Iat Sensor Inspection
300
Iat Sensor Removal and Installation
300
Ect Sensor Inspection
300
Ect Sensor Removal and Installation
300
To Sensor Inspection
300
To Sensor Removal and Installation
300
Ho2 Sensor Inspection (for E-02, 19, 24)
301
Ho2 Sensor Removal and Installation (for E-02, 19, 24)
301
Fuel System and Throttle Body
302
Fuel Delivery System
303
Fuel System
304
Fuel Tank Removal
304
Fuel Tank Installation
304
Fuel Pressure Inspection
305
Fuel Pump Inspection
306
Fuel Discharge Amount Inspection
306
Fuel Pump Relay Inspection
307
Fuel Pump and Fuel Level Gauge Removal
308
Fuel Level Gauge Inspection
309
Fuel Pump Disassembly
310
Fuel Mesh Filter Inspection
311
Fuel Pump and Fuel Level Gauge Reassembly and Installation
311
Throttle Body
313
Construction
313
Air Cleaner Box Removal
314
Air Cleaner Box Installation
314
Air Cleaner Chamber and Throttle Body Removal
314
Throttle Body Disassembly
316
Throttle Body Cleaning
318
Inspection
318
Isc Valve Inspection
318
Isc Valve Removal
319
Inspection
319
Isc Valve Installation
319
Throttle Body Reassembly
320
Air Cleaner Chamber and Throttle Body Installation
322
Stp Sensor Adjustment
323
Fuel Injector Removal
323
Fuel Injector Inspection
323
Fuel Injector Installation
324
Throttle Valve Synchronization
324
Throttle Position Sensor (Tps) Setting
325
Exhaust System
326
Excva (Exhaust Control Valve Actuator) and Excv (Exhaust Control Valve)
327
Excva and Excv Removal
327
Excva Inspection
328
Excv Inspection
328
Cable Inspection
328
Excva and Excv Installation
329
Excva Adjustment
331
Exhaust Pipe and Muffler
333
Removal
333
Installation
335
Cooling and Lubrication System
338
Engine Coolant
339
Cooling Circuit
340
Cooling Circuit Inspection
340
Radiator and Water Hose
341
Radiator Removal and Disassembly
341
Radiator Disassembly
342
Radiator Cap Inspection
342
Radiator Inspection and Cleaning
343
Radiator Reassembly
343
Radiator Installation
343
Water Hose Inspection
344
Cooling Fan
345
Inspection
345
Cooling Fan Relay Inspection
345
Ect Sensor
346
Removal
346
Inspection
346
Installation
347
Thermostat
348
Removal
348
Inspection
348
Installation
349
Water Pump
350
Removal and Disassembly
350
Inspection
352
Reassembly and Installation
353
Engine Lubrication System Chart
356
Chassis
358
Exterior Parts
360
Fastener Removal and Installation
360
Front and Rear Seat
361
Frame Side Cover
362
Rear Frame Cover
362
Frame Head Cover and Radiator Cover
363
Front Wheel
365
Construction
365
Removal
366
Inspection and Disassembly
366
Reassembly and Installation
368
Front Fork
371
Construction
371
Removal and Disassembly
372
Inspection
375
Reassembly
376
Installation
379
Steering
380
Construction
380
Removal
381
Inspection and Disassembly
382
Reassembly
383
Installation
383
Steering Tension Adjustment
385
Handlebars
386
Construction
386
Removal
387
Installation
388
Rear Wheel
390
Construction
390
Removal
391
Disassembly
391
Inspection and Disassembly
392
Reassembly and Installation
393
Rear Suspension
397
Construction
397
Removal
398
Inspection and Disassembly
399
Rear Shock Absorber Disposal
402
Reassembly
403
Installation
406
Suspension Setting
407
Front Brake
408
Construction
408
Brake Pad Replacement
409
Brake Fluid Replacement
410
Caliper Removal
411
Caliper Disassembly
412
Caliper Inspection
413
Caliper Reassembly
413
Caliper Installation
415
Brake Disc Inspection
415
Master Cylinder Removal and Disassembly
416
Master Cylinder Inspection
417
Master Cylinder Reassembly
417
Master Cylinder Installation
418
Rear Brake
419
Construction
419
Brake Pad Replacement
420
Brake Fluid Replacement
421
Caliper Removal
422
Caliper Disassembly
422
Caliper Inspection
423
Caliper Reassembly
425
Caliper Installation
426
Master Cylinder Removal
426
Master Cylinder Disassembly
427
Master Cylinder Inspection
428
Master Cylinder Reassembly
428
Master Cylinder Installation
429
Tire and Wheel
430
Tire Removal
430
Inspection
430
Valve Inspection
431
Tire Installation
432
Balancer Weight Installation
433
Electrical System
434
Cautions in Servicing
436
Connector
436
Coupler
436
Clamp
436
Fuse
436
Semi-Conductor Equipped Part
437
Battery
437
Connecting the Battery
437
Wiring Procedure
437
Using the Multi-Circuit Tester
438
Location of Electrical Components
439
Charging System
441
Troubleshooting
441
Inspection
442
Starter System and Side-Stand/Ignition Interlock System
445
Troubleshooting
445
Starter Motor Removal
447
Starter Motor Inspection
449
Starter Motor Reassembly
450
Starter Relay Inspection
451
Side Stand/Ignition Interlock System Parts Inspection
452
Ignition System
455
Troubleshooting
456
Inspection
458
Speedometer and Tachometer
463
Description
463
Speedometer Removal and Disassembly
464
Tachometer Removal and Disassembly
465
Inspection
466
Headlight Relay Inspection
473
Relays
474
Turn Signal/Side-Stand Relay
474
Starter Relay
474
Fuel Pump Relay
474
Cooling Fan Relay
474
Switches Inspection
475
Battery
476
Specifications
476
Initial Charging
476
Servicing
478
Recharging Operation
478
Servicing Information
480
Troubleshooting
482
Fi System Malfunction Code and Defective Condition
482
Engine
486
Radiator (Cooling System)
492
Chassis
493
Shaft Drive
494
Brakes
494
Electrical
495
Battery
496
Special Tools
497
Tightening Torque
501
Cooling System
502
Tightening Torque Chart
504
Service Data
505
Wiring Harness, Cable and Hose Routing
514
Wiring Harness Routing
514
Engine Electrical Parts Lead Wire Routing
516
Cable Routing
517
Front Brake Hose Routing
518
Rear Brake Hose Routing
519
Throttle Body Hose Routing
520
Cooling System Hose Routing
521
Pair (Air Supply) System Hose Routing (for E-03, 28, 33)
522
Pair (Air Supply) System Hose Routing (for the Others)
523
Fuel Tank Installation
524
Frame Head Cover and Radiator Cover Installation
525
Frame Head Cover Cushion Installation
526
Radiator Upper Cover Cushion Installation
526
Left Frame Covers Installation
527
Right Frame Covers Installation
528
Headlight Cover Installation
529
Ignition Coil Installation
530
Side-Stand Installation
530
Rear Turn Signal Light, License Light Wire Routing
531
Seat Lock Cable Routing
531
License Light and License Plate Installation
532
Brake Light/Taillight Installation
532
Emission Control Information
534
Emission Control Systems
535
Fuel Injection System
535
Crankcase Emission Control System
536
Exhaust Emission Control System (Pair System)
537
Inspection
538
Pair Hoses
538
Pair Reed Valve
541
Pair Control Solenoid Valve
541
Pair (Air Supply) System and Emission Control System
538
Pair (Air Supply) System Hose Routing (for E-03, 28, 33)
541
Pair (Air Supply) System Hose Routing (for the Others)
542
Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)
543
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
544
HOSES (EVAP Hose)
544
Evap Canister
544
EVAP CANISTER HOSE ROUTING (Only for E-33)
545
Specifications
547
Brake Light/Taillight
554
Coolant Temperature/Oil Pressure Indicator Light
554
Service Data
564
Fi System Wiring Diagram
573
Ecm Terminal
574
Fail-Safe Function
576
Malfunction Code and Defective Condition
577
Isc Valve Reset
579
C44" (P0156) or "C64" (P0130) O2 SENSOR (O2S) CIRCUIT
580
Malfunction (for E-02, 19, 24, 51)
580
C49" (P1768) or "C61" (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION
583
Wiring Diagram
584
Cable Routing
586
Headlight
596
Position Light
596
Brake Light/Taillight
596
Front Turn Signal Light
596
Rear Turn Signal Light
596
License Light
596
High Beam Indicator Light
596
Turn Signal Indicator Light
596
Neutral Indicator Light
596
Coolant Temperature/Oil Pressure Indicator Light
596
Specifications
598
Rear Wheel
599
Headlight Beam Adjustment
600
Wiring Diagram
601
Wiring Harness Routing
603
Front Brake Hose Routing
605
Front Turn Signal Light
554
Front Turn Signal Light/Position Light
554
High Beam Indicator Light
554
License Light
554
Neutral Indicator Light
554
Position Light
554
Rear Turn Signal Light
554
Turn Signal Indicator Light
554
4
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Suzuki VZR1800 2007 Specifications
General
Brand
Suzuki
Model
VZR1800 2007
Category
Motorcycle
Language
English
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