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C90 Service Manual

1. SPEEDOMETER HAZARD ENGINESTOP STARTER FRONT BRAKE TU TURN SIGNAL INDICATOR LIGHT SWITCH _ SWITCH BUTTON LIGHT SWITCH HIGH BEAM INDICATOR LIGHT SIDE STAND OI OIL PRESSURE INDICATOR LIGHT ILLUMI or SWITCH DECOMP NU NEUTRAL INDICATOR LIGHT SPEED HO2 REARBRAKE RETO SOLENOID FUEL PUMP IL ILLUMINATION SENSOR SENSOR LIGHT SWITCH FREE FI INDICATOR LIGHT DECOMP TO IGNITION IGNITION Ea SENSOR FUEL PUMP a COIL 1 COIL 2 T 225 iL o8 o zz omo Qa o o 5 E orzmm BFS zogez o C ongnh zm zmOnzrzorrLlmO E c 525 03528288220
2. Link type coil spring oil damped Front suspension 140 mm 5 5 in Rear wheel 118 mm 4 6 in une ecl nna metet ees 32 Bc 138 mm 5 43 in Steering angle sse 39 right amp left T rnirig radiLis 2 2 Le 3 1 m 10 2 ft Front brake cen eere eaa Disc brake twin legende Disc brake Front tlle eue eec en Poco aa aaa 150 80 16 M C 71H tubeless Rear tire SIZE sasaka 180 70 15 M C 76H tubeless ELECTRICAL Electronic ignition Transistorized Ignition ii anl aro E 9 B T D C at 1 000 r min Spark plug cir eR NGK DPR7EA 9 or DENSO X22EPR U9 Battery 12 V 64 8 18 Ah 10 HR Generator nitide t REED de dee aaa Three phase A C generator Main TSC Cm 30A USC tsp E NE KAT TAn MEN KAT 10 10 10 15 15 10 A Headlight inrer inion detent 12 V 60 55 W H4 Position Parking light sseessssssssse 12 N 5M Except E 03 24 28 33 Brake light Taillight eeesseeeeee 12 V 21 5 W Front turn signal light eeeesessssssees 12 V 21 5 W E 03 28 33 12 V 24 W
3. 26 FUEL DELIVERY SYSTEM iioii ai ern rea nag aa banana nana anaa Rd anenun ga 28 FI SYSTEM PARTS LOCATION irirnsnscxixsEak kinh xi on opidi dco eal 29 FI SYSTEM WIRING DIAGRAM eere eee nennen nenas aant ttn a aaa a aant tnum nana 31 ECM TERMINAL 5555525545587985 kt n ada ER RERUM D ARR ER Ra RR 32 SELF DIAGNOSIS FUNCTION ranis erant raa aau rra pata nasa assa nisrasaaa ars 33 FAIE SAFE FUNCTION 3455555455554549 48495859955489 a5K 98959 MARRE ERR 9549854507490956 55558709998804 37 SYSTEM TROUBLESHOOTING cccccsssscsscsssnsesssssceensesssereseesenssssesensnssensenees 38 FUEL SYSTEM ccssssssssssscanssretvtsvesnsunsessisvsanasvasvenniseasdiieisenessisvansesssaaciisnenssvesneuaiens 93 THROTTLE BODY sisiissssanassasanirssnanaanantensaiaaszauan E AGRAR ERE EXER ERREUR YI RE VER 102 SENSOR Ke 118 EXTERIOR 88556595987955 5995 ERR RERO idara aana aiaiai EE aiiai 121 FRONT FORK Sroa kant 122 LOCATION OF ELECTRICAL COMPONENTS creen 127 CHARGING SYSTEM iain e A QULUEDY XA AER LU EEAEI FRATRE KR RE 129 AUTOMATIC DECOMPRESSION SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM essere etna 131 IGNITION SYSTEM
4. Fa EXE dr kel Xy E SERE FER aiaiai aaisa 133 SPEEDOMETER iiit aito aida ERA EE EBD ERR 138 141 COPYRIGHT SUZUKI MOTOR CORPORATION 2004 SUZUKI MOTOR CORPORATION 2 VL1500K5 05 MODEL Cl 4pge lcm naa ENENG NT 142 BATTERY e ET eT DRE 143 WIRING HARNESS CABLE AND HOSE 144 EXTERIOR PARTS 153 SPECIAL TOOLS aisi era FR a ati in anaa ae Aaen aeaa Ee aeaea asiana 157 TIGHTENING TORQUE 555656555565698285 50995899 kk nd data i poo ada riiv Rua p epa kn ved aao ci Era 158 SERVICE DATA ao pd gagan eene baci ox c xix Fra MuR DE aan ea Kae I ru Da 159 EMISSION CONTROL SYSTEMS 4 eese esee ee nasse tn anat tn nun an 168 PAIR AIR SUPPLY SYSTEM 172 PAIR AIR SUPPLY SYSTEM 174 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 175 HEATED OXGEN SENSOR HO2S INSPECTION FOR E 02 19 24 176 WIRING DIAGRAM toil randa tt 177 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s COUNTR
5. VL1500K5 05 MODEL 169 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the breather hose air cleaner and throttle body D PAIR control solenoid valve EXHAUST GAS PCV hose O FUEL AIR MIXTURE amp FRESH AIR BLOW BY GAS 170 VL1500K5 05 MODEL EXHAUST EMISSION CONTROL SYSTEM PAIR SYSTEM The exhaust emission control system is composed of the PAIR system and THREE WAY CATALYST sys tem For E 02 19 24 and 33 The fresh air is drawn into the exhaust port through the PAIR solenoid valve and PAIR reed valve The PAIR solenoid valve is operated by the ECM and the fresh air flow is controlled according to the TPS EOTS IATS IAPS and CKPS CD PAIR control solenoid valve HO2 sensor E 02 19 24 2 PAIR reed valve D Three way catalyst E 02 19 24 33 Fresh air from air cleaner box amp FRESH AIR 4 Fuel injector EXHAUST GAS ECM VL1500K5 05 MODEL 171 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED Local law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any n
6. VL1500K5 05 MODEL 133 IGNITION SYSTEM Engine stop switch D Side stand Power source 7 relay circuit Ignition coil Spark plug i Fuse 1 gt lt o Ignition switch CKP sensor Wave form arrangement circuit 2 Fuse Battery NOTE The fuel cut off circuit is incorporated in this ECM in order to prevent over running of engine When engine speed reaches 5 800 6 000 r min during running this circuit cuts off fuel at the fuel injector TROUBLESHOOTING No spark or poor spark NOTE Check that the transmission is in neutral and the engine stop switch is in the RUN position Squeeze the clutch lever Check that the fuse is not blown and the battery is fully charged before diagnosing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition switch couplers YES Go to Step 2 NO Poor connection of couplers 134 VL1500K5 05 MODEL Step 2 1 Measure the battery voltage between input lead wires at the ECM with the ignition switch in the ON position E 02 19 24 O G and B W E 03 28 33 O W and B W Is the voltage OK Go to Step 3 Faulty ignition switch Faulty turn signal side stand relay Faulty engine stop switch Broken wire harness or poor connection of related circuit couplers Step 3 1 Measure the ignition coil primary peak volta
7. Manual 6 3 and disconnect the ECM coupler E og o on 8 Check the continuity between Y W wire B and terminal 4 INI SN e Oe 9 Also check the continuity between Red wire and terminal L STPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK Go to Step 1 77 and Go to Step 2 Red or Y W wire open or Y W wire shorted to ground 10 After repairing the trouble clear the DTC using SDS tool C Page 42 80 11500 5 05 MODEL Step 2 1 Turn the ignition switch OFF 2 Remove the air cleaner box C s 103 3 Disconnect the STP sensor coupler 4 Check the continuity between each terminal and ground STP sensor continuity Q Infinity Terminal Ground 5 If OK then measure the STP sensor resistance at the wire terminals between Yellow wire and Black wire B 6 Close and open the secondary throttle valve by finger and measure the valve closing and opening resistance STP sensor resistance Secondary throttle valve is closed Approx 0 5 KQ Secondary throttle valve is opened Approx 3 9 KQ Yellow Black B 7 If OK then measure the STP sensor resistance at the wire terminals between Blue wire C and Black wire B STP sensor resistance Approx 4 69 09900 2500
8. To fuel tank To fuel delivery pipe VL1500K5 05 MODEL 95 FUEL PUMP INSPECTION Turn the ignition switch and check that the fuel pump operates for few seconds If the fuel pump motor does not make operating sound inspect the fuel pump circuit connections or inspect the fuel pump relay and tip over sensor If the fuel pump relay tip over sensor and fuel pump circuit connections are OK the fuel pump may be faulty replace the fuel pump with a new one FUEL DISCHARGE AMOUNT INSPECTION Gasoline is highly flammable and explosive Keep heat spark and flame away e Remove the seats L7 Page 121 Remove the speedometer and fuel inlet cover CC VL1500 Service Manual 6 3 Remove the left frame head cover and left frame upper cover CC VL1500 Service Manual 6 3 e Disconnect the fuel feed hose from the fuel delivery pipe Place the measuring cylinder and insert the fuel feed hose end into the measuring cylinder e Disconnect the fuel pump lead wire coupler 2 96 VL1500K5 05 MODEL Connect a proper lead wire into the fuel pump lead wire cou pler fuel pump side and apply 12 volts to the fuel pump between Y R wire and B W wire for 10 seconds and mea sure the amount of fuel discharged Battery terminal Yellow with red tracer Battery C terminal Black with white tracer If the pump does not discharge the amount specified it means that the fuel pump
9. Remove the No 1 and No 2 PAIR pipes e Remove the air cleaner box 7 Page 103 Remove the throttle body Page 104 16 11500 5 05 MODEL ENGINE INSTALLATION Installation is in the reverse order of removal procedure Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque CAUTION Replace the gaskets with the new ones Adjust the following items to the specification Engine oil 11500 Service Manual 2 6 Throttle valve synchronization C s Page 114 Throttle cable play gt Page 9 Engine idle speed Cs Page 8 Automatic decompression cable C 7 VL1500 Service Manual 2 8 Clutch air bleeding VL1500 Service Manual 6 59 Wiring harness cables and hoses C s Page 144 VL1500K5 05 MODEL 17 ENGINE DISASSEMBLY AND REASSEMBLY The engine disassembly and reassembly procedures are differ ent from those of the VL1500K4 04 MODEL For details other than the following parts refer to the VL1500 Service Manual GEAR POSITION SWITCH REMOVAL Remove the gear position switch D GEAR POSITION SWITCH REASSEMBLY Apply SUZUKI SUPER GREASE A to the O ring When installing the gear position switch D align the pin A with the hole in the gearshift cam retainer CAUTION Use a new O ring to prevent oil leakage MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 2
10. Remove the seats D C 7 Page 121 e Remove the speedometer and fuel inlet cover C VL1500 Service Manual 6 3 e Remove the left frame head cover 3 and left frame upper cover 4 VL1500 Service Manual 6 3 Inspect the fuel feed hose for damage and fuel leakage If any defect is are found the fuel feed hose must be replaced ENGINE IDLE SPEED Inspect initially at 1 000 km 600 miles 2 months and every 6 000 km 4 000 miles 12 months NOTE Warm up the engine before adjusting the engine idle speed e Adjust the throttle cable play 7 Below Remove the left frame upper cover VL1500 Service Manual 6 3 Start the engine turn the throttle stop screw D and set the engine idle speed as follows Connect the multi circuit tester to the high tension cord Engine idle speed 1 000 100 r min 09900 25008 Multi circuit tester set VL1500K5 05 MODEL 9 THROTTLE CABLE PLAY Inspect initially at 1 000 km 600 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter Adjust the throttle cable play with the following three steps MINOR ADJUSTMENT First step e Loosen the lock nut D of the throttle returning cable and turn in the adjuster fully into the threads Second step Loosen the lock nut 4 of the throttle pulling cable Turn the adjuster in or out until the throttle cable play at the throttle grip is betwee
11. YES Odometer 1 and FI light turns ON FI letters Engine can start 2 Each 2 sec Odometer 1 and are indi cated alternately Fl is indicated continuously Engine can not start FI letter FI light turns ON 8 and blinks 1 Current letter displayed any one of the Odometer Tripmeter or Clock 2 When one of the signals is not received by ECM the fail safe circuit works and injection is not stopped In this case FI and Odometer 1 are indicated in the LCD panel and motorcycle can run However when starter relay signal is not received by ECM the engine can not be restarted 8 The injection signal is stopped when the crankshaft position sensor signal tip over sensor signal both 1 2 ignition signals both 1 2 injector signals fuel pump relay signal or ignition switch signal is not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speed ometer does not receive any signal from ECM and the panel indicates If CHEC is indicated the LCD does not indicate the trouble code It is necessary to check the wir ing harness between ECM and speedometer couplers The possible c
12. 108 TP sensor setting procedure 36 STP SENSOR INSPECTION The secondary throttle position sensor is installed on the No 2 throttle body Page 77 STP SENSOR REMOVAL INSTALLATION Remove the right frame head cover and right frame upper cover 2711500 Service Manual 6 3 e Disconnect the coupler D and remove the STP sensor 09930 11950 Torx wrench Install the STP sensor to the No 2 throttle body 108 e STP sensor setting procedure Page 110 VL1500K5 05 MODEL 119 CKP SENSOR INSPECTION The signal rotor is mounted on the generator rotor and crank shaft position sensor is installed at the inside of the generator cover C54 VL1500 Service Manual 3 16 CKP SENSOR REMOVAL INSTALLATION EC VL1500 Service Manual 3D 4 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the front right side of the air cleaner box 66 IAT SENSOR REMOVAL INSTALLATION Remove the right frame head cover and right frame upper cover C7 VLI500 Service Manual 6 3 e Disconnect the IAT sensor coupler D and remove the IAT sensor Installation is in the reverse order of removal V IAT sensor 20 N m 2 0 kgf m 14 4 Ib ft EOT SENSOR INSPECTION The engine oil temperature sensor is installed at the right crank case C7 Page 62 EOT SENSOR REMOVAL INSTALLATION e Disconnect the EOT sensor coupler D and remove the EOT sensor 2 Installat
13. Hydrocarbons Heated Oxygen Sensor HO2S Intake Air Pressure Sensor IAPS Intake Air Temperature Sensor IATS Ignition Liquid Crystal Display Light Emitting Diode Malfunction Indicator Lamp Left Hand 4 VL1500K5 05 MODEL M T MAL Code Max MIL Min NOx OHC OPS PCV RH ROM SAE STC System STP Sensor ST Valve STV Actuator TO Sensor TP Sensor Malfunction Code Diagnostic Code Maximum Malfunction Indicator Lamp LED Minimum Nitrogen Oxides Over Head Camshaft Oil Pressure Switch Positive Crankcase Ventilation Crankcase Breather Right Hand Read Only Memory Society of Automotive Engineers Secondary Throttle Control System STCS Secondary Throttle Position Sensor STPS Secondary Throttle Valve STV Secondary Throttle Valve Actuator STVA Tip Over Sensor TOS Throttle Position Sensor TPS VL1500K5 05 MODEL 5 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ss aaa Tah aa aaa a a aa aa 2 525 mm 99 4 in Overall 1 995 mm 40 2 in E 24 Overall Widths iiir iiinis 1020 mm 40 2 Others Overall height 1 125 mm 44 3 in Wheelbase ie tinere 1 700 mm 66 9 in Ground 140mm 5 5in Seat
14. yub Joyeolpul WOA yous YoUMs dois 1109 91 SO ry jang SOL 40sues 1eno di Josues exeiul uonisod 541 Josues uonIsod e noJu gt S103 10sues aunyesedwa N mooo YI H Savi Josues eJnsseJd Jeo d ELIO Savi Josues eJnsseiJd exeju 104014 499 a Sd LS 10sues pi 32 VL1500K5 05 MODEL ECM TERMINAL TERMINAL NO amp 3 amp 9 Gb 6 amp 49 d d 5 CIRCUIT GP switch signal GP IAT sensor signal IAT p amp 6 d 4 3 2 9 9 D 9 2 D 6 G5 G2 Gp G0 Q9 Q9 Q9 C3 C2 Cb Q9 9 9 TERMINAL 8 CIRCUIT Ignition switch signal AT EOT sensor signal EOT Rear cylinder IAP sensor signal IAP R TO sensor signal TOS STP sensor signal STP TP sensor signal TP Blank Front cylinder IAP sensor signal IAP F Power source for sensors VCC HO2 sensor signal HO2S For E 02 19 24 8 control selector EXS For E 02 19 24 Mode select switch MS Clutch lever position switch CLP Starter switch STA CKP sensor signal CKP Neutral switch NT Power source for fue
15. Plug cap Terminal Ignition coil primary peak voltage Front 180 V and more 180 V and more B Y Ground W Ground Generator coil resistance Generator Max output 0 1 1 00 375 W at 5000 r min W W Generator no load voltage when engine is cold 80 V AC and more at 5 000 r min Regulated voltage 13 5 15 0 V at 5 000 r min Decomp solenoid resistance 0 1 1 5Q Fuel pump resistance 70 1100 Starter relay resistance 3 6Q GP switch voltage 0 6 V and more From 1st to top Battery Type designation FTZ16 BS 1 Capacity 12 V 64 8 18 Ah 10 HR Fuse size HI 10A Headlight eadlig LO 10A Signal 15A Ignition 15A Fuel 10A Power source 10A Main 30A VL1500K5 05 MODEL 165 WATTAGE Unit W SPECIFICATION E 03 28 33 E 24 Headlight 60 lt 55 lt Position Parking light Brake light Taillight Turn signal light Speedometer light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light Fl indicator light WHEEL Unit mm in ITEM STANDARD Rear brake pedal height Brake disc thickness Brake disc runout 15 870 15 913 Front 0 6248 0 6265 12 700 12 743 Rear 0
16. 7 Remove the left frame upper cover C gt VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between W G wire and terminal D 9 Also check the continuity between B Br wire B and terminal 4 HO2S lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 When indicating C44 P0130 W G wire shorted to ground or W G or B Br wire open 10 After repairing the trouble clear the DTC using SDS tool 42 Step 2 When indicating C44 P0130 1 Connect the ECM coupler and HO2 sensor coupler 2 Warm up the engine enough 3 Measure the HO2 sensor output voltage between W G wire and B Br wire when idling condition HO2 sensor output voltage at idle speed 0 4 V and less D W G C B Br 4 If OK then pinch the PAIR hose D with a proper hose clamp 5 Measure the HO2 sensor output voltage while holding the engine speed at 5 000 r min HO2 sensor output voltage at 5 000 r min 0 6 V and D W G 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage ECM coupler Harness side VL1500K5 05 MODEL 89 Is the voltage OK 2 W G wire or B Br wire open or shorted to EUM c
17. VL1500K5 05 MODEL 101 INSTALLATION Install the fuel pump in the reverse order of removal and pay attention to the following points Install the new O ring and apply grease to it The O ring must be replaced with a new one to prevent fuel leakage MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the fuel pump assembly CAUTION Be careful not to bend the fuel level gauge When installing the fuel pump assembly first tighten all the fuel pump assembly mounting bolts lightly and then to the specified torque in the ascending order of numbers m Fuel pump mounting bolt 10 N m 1 0 kgf m 7 3 Ib ft NOTE Apply a small quantity of the THREAD LOCK to the thread por tion of the fuel pump mounting bolt 99000 32050 THREAD LOCK 1342 102 VL1500K5 05 MODEL THROTTLE BODY CONSTRUCTION D STP sensor Fast idle screw 2 TP sensor IAP sensor 3 Fuel delivery pipe ISTP sensor mounting screw V Fuel delivery pipe joint hose TP sensor mounting screw ITEM Nem kgf m Ib ft Fuel injector Fuel delivery pipe joint hose A 3 5 0 35 2 5 O ring mounting screw 3 5 0 35 2 5 Cushion seal Fuel delivery pipe mounting 3 5 0 35 2 5 Throttle stop screw Q screw D 3 5 0 35 2 5 VL1500K5 05 MODEL
18. 05 MODEL 157 09915 74511 Oil pressure gauge 158 VLI500K5 05 MODEL TIGHTENING TORQUE FI SYSTEM AND INTAKE AIR SYSTEM ITEM Pam CHASSIS ITEM Nm SERVICE DATA VALVE GUIDE Valve diam STANDARD 11500 5 05 MODEL 159 Unit mm in LIMIT Lash adjuster plunger stroke Valve guide to valve stem clearance 0 010 0 037 0 0004 0 0015 0 040 0 070 0 0016 0 0028 Valve stem deflection Valve guide 5 500 5 512 0 2165 0 2170 7 000 7 015 0 2756 0 2762 5 475 5 490 0 2156 0 2161 6 945 6 960 0 2734 0 2740 Valve stem runout Valve head thickness Valve stem end length Valve seat width IN 0 9 1 1 i 0 035 0 043 1 0 1 2 0 039 0 047 Valve head radial runout 0 03 IN amp EX 0 001 Valve spring free length __ 35 0 INTAKE INNER 1 38 37 8 OUTER 1 49 Valve spring free length A 40 6 EXHAUST 1 60 Valve spring tension INTAKE 53 65 N 5 3 6 5 kgf INNER 11 68 14 33 Ibs at length 28 0 mm 1 10 in 140 142 N 14 0 14 2 kgf OUTER 30 86 31 31 Ibs at length 31 5 mm 1 24 in Valve spring tension EXHAUST 203 233 N 20 3 23 3 kgf 44 75 51 37 Ibs at length 35 0 mm 1 38 in 160 11500 5 05 MODEL CAMSH
19. 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal 49 or sub harness coupler Open or short circuit in the B BI wire or B Br wire or sub harness VL1500K5 05 MODEL 59 Step 1 When indicating P0115 H 1 Turn the ignition switch OFF 2 Check the EOT sensor coupler for loose or poor contacts If OK then check the EOT sensor lead wire continuity 7 3 Remove the left frame upper cover C VL1500 Service Manual 6 3 4 Disconnect the EOT sensor and coupler 5 Check the continuity between B BI wire and terminal 49 N s 6 Also check the continuity between B G wire and terminal 4 EOTS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK E Go to Step 2 Sub harness B BI B Br wire or sub harness B Bl or B G A n wire open P B Ss y Loose or poor contacts on the sub harness cou EOT ECM pler B G B Br 7 After repairing the trouble clear the DTC using SDS tool C Page 42 60 VL1500K5 05 MODEL Step 1 When indicating P0115 L 1 Turn the ignition switch OFF 2 Check the EOT sensor coupler for loose or po
20. For E 03 24 28 33 Horn lead wire Generator lead wire For E 02 19 Put lead wire into the space HO2 sensor lead wire For E 02 19 24 Clamp Horn Except for E 03 24 28 33 Wiring harness 8 Clutch VL1500K5 05 MODEL 147 CABLE AND HOSE ROUTING Wiring harness S Throttle cable No 2 N Wiring harness ge Say V Throttle ls No 1 Y Clutch hose 40 mm 160 mm 1 57 in 6 30 in Throttle cable No 1 Clutch hose CR Throttle cable No 2 Wiring harness Clutch hose Throttle cable No 1 NN WH M NM N N ML HiH W N WW i NA Ma Vi 1 AL Throttle cable No 2 Wiring harness Clamp Throttle cables and wiring harness must be passed under the clutch hose 148 VL1500K5 05 MODEL FRONT BRAKE HOSE ROUTING After the brake hose union has contacted the stopper tighten the union bolt to the specified torque Pass through the brake hose inside of the hose guide After positioning the hose clamp with stopper tighten the clamp bolt Bind the brake hose together with the wire harness by the wire clamp Clamp the brake hose firmly VL1500K5 05 MODEL 149 REAR BRAKE HOSE ROUTING After the brake hose union has contacted the stopper After
21. 103 AIR CLEANER BOK REMOVAL Remove the seats D C Page 121 e Remove the speedometer and fuel inlet cover D frame head covers 3 and frame upper covers CC VL1500 Service Manual 6 3 Loosen the throttle body clamp screws e Disconnect the IAT sensor coupler e Disconnect the PCV hose and PAIR hose 104 VL1500K5 05 MODEL THROTTLE BODY REMOVAL e Remove the air cleaner box 103 Disconnect the throttle cables from their drum CAUTION After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle valve and throttle body Disconnect the STP sensor coupler and STVA coupler 2 Place a rag under the fuel feed hose and disconnect the fuel feed hose from the delivery pipe Disconnect the fuel injector couplers Loosen the throttle body clamp screws at the intake pipe side VL1500K5 05 MODEL 105 e Disconnect the TP sensor coupler and IAP sensor vacuum hoses 6 Remove the throttle body assembly THROTTLE BODY DISASSEMBLY e Remove the fuel delivery pipe joint hose Remove the fuel delivery pipes Remove the fuel injectors 106 VLI500K5 05 MODEL e Remove the TP sensor 3 and STP sensor with the special tool 09930 11950 Torx wrench NOTE Prior to disassembly mark each sensor s original position with a paint or scribe for acc
22. 11 000 14 500 Item months 2 12 24 36 48 Air cleaner element R Exhaust pipe nuts and muffler bolts T T T Spark plugs R R Fuel hose Replace every 4 years Engine oil R R R R R Engine oil filter R R Engine idle speed Throttle cable play Automatic decompression cable Throttle valve synchronization Sat e E 33 only Evaporative emission control system 33 only Replace vapor hose every 4 years PAIR air supply system Clutch hose Replace every 4 years Clutch fluid Replace every 2 years Final gear oil R Brakes Brake hose Replace every 4 years Brake fluid Replace every 2 years Tires Steering Front forks Rear suspension Chassis bolts and nuts NOTE Inspect and clean adjust replace or lubricate as necessary R Replace Tighten Item marked with asterisk is exclusive to VL1500K5 05 MODEL 8 VL1500K5 05 MODEL MAINTENANCE AND TUNE UP PRO CEDURES This section describes the servicing procedures for each Peri odic Maintenance item which differ from those of the VL1500K4 04 MODEL For details other than the following items refer to the chapter 2 of Service Manual FUEL HOSE Inspect every 6 000 km 4 000 miles 12 months Replace every 4 years
23. 2 175 thickness 0 0758 0 0856 Crankshaft thrust clearance 0 05 0 10 0 002 0 004 Crankshaft runout 162 VLI500K5 05 MODEL OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1 154 76 51 x 31 40 Oil pressure at 60 140 Above 350 kPa 25 kgf cm 50 psi Below 650 kPa 6 5 kgf cm 92 psi CLUTCH Drive plate thickness at 3 000 r min STANDARD 2 90 3 10 0 114 0 122 Unit mm in LIMIT Drive plate claw width 15 6 15 8 0 614 0 622 Driven plate distortion Clutch spring free length 34 47 1 357 Clutch master cylinder bore 14 000 14 043 0 5512 0 5529 Clutch master cylinder piston diam 13 957 13 984 0 5495 0 5506 Clutch release cylinder bore 33 600 33 662 1 3228 1 3253 Clutch release cylinder piston diam DRIVE TRAIN ITEM 33 550 33 575 1 3209 1 3218 STANDARD Primary reduction ratio 1 490 76 51 Secondary reduction ratio 0 852 29 34 Final reduction ratio 2 666 19 19 x 32 12 Gear ratios Low 3 000 36 12 2nd 1 823 31 17 ard 4th 1 333 28 21 1 041 25 24 Top 0 884 23 26 Shift fork to groove clearance 0 1 0 3 0 004 0 012 Shift fork groove width 5 50 5 60 0 217 0 220 Shift fork thi
24. 4 8 V In other than the above range C14 P0120 is indicated CHECK FOR CKP sensor wiring and mechan ical parts CKP sensor lead wire coupler connection IAP sensor lead wire coupler connection TP sensor lead wire coupler connection Sensor voltage is higher than specified value Sensor voltage is lower than specified value The sensor voltage should be the fol lowing 0 1 V x sensor voltage 4 6 V In other than the above range C15 P0115 is indicated TP sensor circuit shorted to VCC or ground circuit open TP sensor circuit open or shorted to ground or VCC circuit open EOT sensor lead wire coupler connection Sensor voltage is higher than specified value EOT sensor circuit open or ground circuit open Sensor voltage is lower than specified value Decomp relay signal is not input to ECM Starter relay signal is not input to ECM EOT sensor circuit shorted to ground Decomp relay lead wire coupler connection Starter relay lead wire coupler connection 24 25 P0351 P0352 DETECTED ITEM IAT sensor TO sensor Ignition sig nal Secondary throttle valve actuator STP sensor DETECTED FAILURE CONDITION The sensor voltage should be the fol lowing 0 1 V lt sensor voltage lt 4 6 V In other than the above range C21 P0110 is indicated VL1500K5 05 MODEL 45 CHECK FOR IAT sensor lead wi
25. 40 mm ES 0 79 1 57 in Q IK SN 4 D LAJU 0 59 9 79 in E PAIR control solenoid valve with PAIR reed valve Connect the air hose to the air cleaner box Matching mark yellow Matching mark white Cushion seat Apply adhesive agent to the cushion seat Wiring harness 176 VL1500K5 05 MODEL HEATED OXGEN SENSOR HO2S INSPECTION FOR E 02 19 24 1 The HO2 sensor coupler is located at the rear side of the fuel tank Page 87 y Inspect the HO2 sensor and its circuit referring to flow table of the malfunction code C44 P0130 P0135 e Check the resistance between the terminals of the HO2 sen sor Resistance 6 5 8 9 Q at 23 C 73 4 F White White 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is not within the standard range replace the HO2 sensor with a new one NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature Do not remove the HO2 sensor while it is hot CAUTION Be careful not to expose it to excessive shock Do not use an impact wrench while removing or installing the HO2 sensor unit Be careful not to twist or damage the sensor lead wire WIRING DIAGRAM E 02 19 24 HANDLEBAR SWITCH R
26. 5000 0 5017 15 827 15 854 Front 0 6231 0 6242 12 657 12 684 Rear 0 4983 0 4994 30 230 30 306 Elon 1 1902 1 1931 30 230 30 306 Hear 1 1902 1 1931 30 150 30 200 Front 1 1870 1 1890 30 150 30 200 Rear 1 1870 1 1890 Master cylinder bore Master cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam Wheel rim runout Axial eu Radial Wheel axle runout Front Rear 166 11500 5 05 MODEL Wheel rim size Tire size STANDARD 16 x MT3 50 16M C x MT3 50 15M C x MT5 00 150 80 16 71H 150 80 16M C 71H 180 70 15M C 76H Tire tread depth Front __ 06 2 0 Rear 0 08 SUSPENSION Unit mm in ITEM STANDARD Front fork stroke 140 5 5 Front fork spring free length 601 5 23 68 Front fork oil level 192 7 56 Rear shock absorber spring set length Rear wheel travel TIRE PRESSURE COLD INFLATION TIRE PRESSURE 222 0 8 74 SOLO RIDING DUAL RIDING kPa kgf cm psi kPa kgf cme psi FRONT 200 2 00 29 200 2 00 29 REAR 250 2 50 36 250 2 50 36 FUEL OIL SPECIFICATION Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline containin
27. ACCELERATION SIGNAL DECELERATION SIGNAL INJECTION STOP CONTROL SIGNAL During acceleration the fuel injection time volume is increased in accordance with the throttle opening speed and engine rpm During deceleration the fuel injection time volume is decreased DESCRIPTION TIP OVER SENSOR SIGNAL FUEL SHUT OFF When the motorcycle tips over the tip over sensor sends a signal to the ECM Then this signal cuts OFF current sup plied to the fuel pump fuel injectors and ignition coils OVER REV LIMITER SIGNAL The fuel injectors stop operation when engine rpm reaches rev limit rpm 28 VLI500K5 05 MODEL FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel tank fuel pump fuel filters fuel feed hose fuel delivery pipe including fuel injectors and fuel pressure regulator There is no fuel return hose The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe Fuel pressure is regulated by the fuel pressure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 300 kPa 3 0 kgf cm 43 psi the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator flows back to the fuel tank
28. Connect the throttle pulling cable and throttle returning cable to the throttle cable drum Loosen each throttle cable lock nut Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance is 0 2 mm 0 0 08 in Tighten each lock nut Adjust the throttle cable play Refer to page 9 for details AIR CLEANER BOX INSTALLATION Installation is in the reverse order of removal Pay attention to the following points Install the air cleaner box and tighten the throttle body clamp screws as shown in the illustration STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary measure the sensor resistance and adjust the STP sensor position as follows e Remove the air cleaner box Page 103 Disconnect the STVA coupler and STP sensor coupler 74 and 77 Close the secondary throttle valve by finger and measure the STP sensor resistance STP sensor setting resistance ST valve is fully closed Approx 0 5 KQ Yellow Black 09900 25008 Multi circuit tester set Tester knob indication Resistance Q 0 2mm LEFT SIDE e f the STP sensor resistance is out of specification loosen the STP sensor mounting screw and adjust the STP sensor resis tance to specification Tighten the STP sensor mounting screw 09930 11950 Torx wrench 5 STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 lb ft FUEL INJ
29. Es 17 88 o Sea 35 7 SEE S655S7 5 S55 Rezsco IRE 2558 5S 35 FRONT TURN SIGNAL LIGHT X Lbl Lg ZX M AA GAN B W B W N 55 98 BRAKE LIGHT HEADLIGHT Lg TAILLIGHT el Y WIB WIB B W B W B W WwW Br Gr B FRONT TURN SIGNAL LIGHT L L E L NI NUNC 00 o qvi p EE B B 1 oke I 89 GIE Br Br B W B W POSITION LIGHT For E 02 19 N mo Only for E 24 Gin T so m Ex Li m BE 3soicES ag FEES ago amp amp z rr2E 5 mmmmm LQmo ET 8 go m om tt Ld mcm 501 to BOZZE gantS2 oo 3 9 SENSOR SENSOR HORN HORN H HORN L HORN PASSING DIMMER CLUTCH OXO INJECTOR T FRONT REAR O STARTER BUTTON TURNSIGNAL LIGHT SWITCH LEVER 1 INJECTOR SENSOR MOTOR STARTER LIGHT SWITCH SWITCH POSITION IGNITION SWITCH GP STV ACTUATOR 2 RELAY BATTERY SWITCH SWITCH GENERATOR REGULATOR RECTIFIER SOLENOID HANDLEBAR SWITCH L FUSE BOX VALVE 1 HEAD 10A 2 HEADLO 10A OIL 3 FUEL 10A EOT PRESSURE 4 IGNITION 15A SENSOR SWITCH 5 SIGNAL 15 6 P SOURCE 10A E 03 28 33 HANDLEBAR SWITCH R SPEEDOMETER HAZARD ENGINESTOP STARTER FRONT BRAKE TU TURN SIGNAL INDICATOR LIGHT SWITCH SWITCH BUTTON LIGHT SWITCH HI HIGH BEAM INDICATOR LIGHT SIDE STAND OI OIL PRESSURE INDICATOR LIGHT SWITCH NU NEUTRAL INDICATOR LIGHT IL ILLUMINATION FI INDICATOR LIGHT SENSOR
30. MODEL Step 1 When indicating PO110 L 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the IAT sensor coupler for loose or poor contacts If OK then check the IAT sensor lead wire continuity 4 Disconnect the IAT sensor coupler 5 Check the continuity between Dg wire D and ground If the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Measure the voltage between Dg wire D and ground IAT sensor output voltage 0 1 4 6 V Dg Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Are the continuity and voltage OK Go to Step 2 Dg wire shorted to ground f wire is OK go to Step 2 8 After repairing the trouble clear the DTC using SDS tool 42 VL1500K5 05 MODEL 69 Step 2 1 1 Turn the ignition switch OFF 2 Measure the IAT sensor resistance IAT sensor resistance Approx 2 45 kQ at 20 68 F Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 1 Dg or B Br wire open or shorted to ground or poor or connection If wire and connection are OK intermittent
31. OK then measure the PAIR control solenoid valve resis tance 3 Disconnect the PAIR control solenoid valve coupler 4 Measure the resistance between Black and Black wire termi nals PAVN PAIR valve resistance 20 24 Q at 20 30 68 86 F Black Black 09900 25008 Multi circuit tester set Tester knob indication Resistance Q 5 If OK then check the continuity between each terminal and ground PAIR valve resistance lt lt Q Infinity Terminal Ground Tester knob indication Resistance Is the resistance OK YES Go to Step 2 NO Replace the PAIR valve with a new one 92 11500 5 05 MODEL 6 After repairing the trouble clear the DTC using SDS tool CC Page 42 Step 2 1 Turn the ignition switch ON 2 Measure the voltage between O W wire and ground PAIR valve voltage Battery voltage O W Ground 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Br B wire open or shorted to ground or poor 1 connection f wire and connection are OK intermittent trou ble or faulty ECM e Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again YES NO Open or short circuit in the O W wire 3 After repairing the trouble clear the DTC using SDS tool CC Page 42 ACTIVE CONTROL INSPECTION 1 Set up the
32. SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click PAIR Sol operating control D 4 Click each button At this time if an operation sound is heard from the PAIR control solenoid valve the function is normal ECM coupler Harness side Active control menu PAIR Sol operating control Secondary throttle operating control Decomp sol operating control Quit Battery voltage 00 V Gear position N Secondary throttle actuator position sensor DAE PAIR control solenoid valve Ignition switch signal Tip over sensor Off Clutch switch signal On Off Starter signal PAIR Sol operating control 5 FUEL SYSTEM FUEL TANK REMOVAL Remove the seats D Page 121 Remove the speedometer and fuel inlet cover CC VL1500 Service Manual 6 3 Remove the frame head covers 3 and frame upper covers 4 CC VL1500 Service Manual 6 3 Remove the frame covers C7 VL1500 Service Manual 6 2 Remove the PAIR cover PAIR control valve and PAIR bracket 2 Page 14 Remove the exhaust pipes and mufflers 6 27 VL1500 Service Manual 3 5 Remove the heat shield bolt and fuel tank mounting bolts VL1500 Service Manual 5 2 Remove the right frame handle grip D and seat frame
33. TPS 1 C15 Engine oil temp sensor EOTS C17 Intake air pressure sensor 1 IAPS 1 For Rear cylinder C18 Decomp control system C19 Starter control system C21 Intake air temp sensor IATS C23 Tip over sensor TOS C24 Ignition signal 1 IG coil 1 For Rear cylinder C25 Ignition signal 42 IG coil 42 For Front cylinder C28 Secondary throttle valve actuator STVA C29 Secondary throttle valve position sensor STPS 2 C31 Gear position signal GP switch C32 Injector signal 1 FI 1 For Rear cylinder C33 Injector signal 2 FI 2 For Front cylinder C41 Fuel pump control system FP control system Fuel pump fuel pump relay C42 Ignition switch signal IG switch signal Anti theft C44 Heated oxygen sensor HO2S For E 02 19 24 C49 _ PAIR control solenoid valve PAIR valve In the LCD DISPLAY panel the malfunction code is indicated from small code to large code 1 To get the proper signal from the throttle position sensor the sensor basic position is indicated in the LCD DISPLAY panel The malfunction code is indicated in three digits In front of the three digits a line appears in any of the three positions upper middle or lower line If the indication is upper or lower line when engine rpm is 1 000 r min slightly turn the throttle position sensor and bring the line to the middle In the normal condition the throttle valve stop screw pushes throttle valves slightly and middle line will be i
34. and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the ECT sensor with a new one 4 After repairing the trouble clear the DTC using SDS tool C Page 42 EOT sensor specification Engine Oil Temp Resistance 20 68 F Approx 61 3 50 122 Approx 17 8 kQ 80 C 176 F Approx 6 2 kQ 110 C 230 F Approx 2 5 kQ 62 VL1500K5 05 MODEL EOT SENSOR INSPECTION e Remove the EOT sensor 119 Check the EOT sensor by testing it at the bench as shown in the figure Connect the EOT sensor f to a circuit tester and place it in the oil contained in a pan which is placed on a stove Heat the oil to raise its temperature slowly and read the col umn thermometer 3 and the ohmmeter f the EOT sensor ohmic value does not change in the propor tion indicated replace it with a new one EOT sensor specification Engine Oil Temp Resistance 20 C 68 F Approx 61 3 50 C 122 F Approx 17 8 kQ 80 C 176 F Approx 6 2 kQ 110 C 230 F Approx 2 5 kQ 09900 25008 Multi circuit tester set Tester knob indication Resistance Q If the resistance is noted to show infinity or too much different resistance value replace the EOT sensor with
35. injury may result VL1500K5 05 MODEL 21 Ignition S W INCORRECT 22 VL1500K5 05 MODEL ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows As the cause can exist in the connector coupler or terminal they need to be checked carefully Loose connection of connector coupler Poor contact of terminal due to dirt corrosion or rust poor contact tension entry of foreign object etc Wire harness being open Poor terminal to wire connection Disconnect the negative cable from the battery Check each connector coupler at both ends of the circuit being checked for loose connection Also check for condition of the coupler lock if equipped Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully inserted in the coupler and locked If contact tension is not enough rectify the contact to increase tension or replace The terminals must be clean and free of any foreign material which could impede proper terminal con
36. is defective or that the fuel filter is clogged Fuel discharge amount 168 ml and more 10 sec 5 7 5 9 US Imp oz 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pump relay is located at the right side of the ECM Remove the left frame head cover C VL1500 Service Manual 6 3 Remove the fuel pump relay First check the insulation between and terminals with pocket tester Then apply 12 volts to O and D terminals to and to D and check the continuity between and B If there is no continuity replace it with a new one FUEL PUMP ASSEMBLY REMOVAL Remove the seats C7 Page 121 e Remove the speedometer and fuel inlet cover VL1500 Service Manual 6 3 e Remove the left frame head cover 3 and left frame upper cover VL1500 Service Manual 6 3 VL1500K5 05 MODEL 97 e Remove the fuel feed hose Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the fuel pump coupler Remove the mounting bolts diagonally Lift up the rear part and turn the fuel pump mounting plate counterclockwise to approx 90 Pull out the fuel pump mounting plate until the pressure regu lator D comes out from the fuel tank Turn the fuel pump mounting plate counterclockwise to approx 35 98 11500 5 05 MODEL Pull the fuel pump mounting plate until the fuel filt
37. known good one and inspect it again If check result is not satisfactory replace TP sen sor with a new one 4 After repairing the trouble clear the DTC using SDS tool Page 42 VL1500K5 05 MODEL 57 R ECM o ECM coupler Harness side 58 VL1500K5 05 MODEL C15 P0115 H L EOT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage is not within the following EOT sensor circuit open or short range EOT sensor malfunction 0 1 lt Sensor voltage lt 4 6 V ECM malfunction P0115 H Sensor voltage is higher than specified e EOT sensor circuit open or ground circuit open value L Sensor voltage is lower than specified EOT sensor circuit shorted to ground value EOT sensor ECM Sub harness v B BI B BI EOT B G B Br E2 INSPECTION Step 1 When indicating C15 1 Turn the ignition switch OFF 2 Check the EOT sensor coupler for loose or poor contacts If OK then measure the EOT sensor voltage at the wire side coupler 3 Disconnect the EOT sensor coupler and turn the ignition switch ON 4 Measure the voltage between B BI wire terminal D and ground 5 Also measure the voltage between B BI wire terminal D and B G wire terminal EOT sensor input voltage 4 5 5 5 V B BI Ground B BI B G
38. positioning the clamp with the stopper tighten the union bolt tighten the clamp bolt Brake hose must be passed over the brake support Brake hose boss and caliper bracket Reservoir tank Wire harness Clamp Frame 150 VLI500K5 05 MODEL FUEL SYSTEM HOSE ROUTING VIEW OF TOP VIEW OF BOTTOM ath ON Surge hose E 33 only IAP sensor Rear cylinder EVAP canister E 33 only EOT sensor Throttle body Fuel feed hose PCV Breather hose IAP sensor vacuum hose Rear cylinder Air cleaner box kgf m Ib ft IAP sensor vacuum hose Front cylinder IAT sensor 2 0 14 4 Purge hose E 33 only IAP sensor Front cylinder 2 2 16 0 VL1500K5 05 MODEL 151 The ends of the clamp should face left side The ends of the clamp The ends of the clamp should face right side should face right side The clamp bolt head sould face downward 2 V 15 0 15 kgf m 1 0 lb ft 2 Water drain hose V 10 Nm 1 0 kgf m 7 0 16 0 9 5 Nm 0 5 kgf m 3 7 Ib ft 152 VL1500K5 05 MODEL PAIR AIR SUPPLY SYSTEM HOSE ROUTING 4 LIT OF 20 40 mm 0 79 1 57 20 40 mm 0 79 1 57 in 9 mi M 4 PAIR control solenoid valve with PAIR reed valve Connect the air hose to the air cleaner box Matching mark Yellow M
39. sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace When taking measurements at electrical connectors using a tester probe be sure to insert the probe from the wire harness side backside of the connector coupler VL1500K5 05 MODEL 19 D Coupler Qo Probe 20 VLI500K5 05 MODEL When connecting meter probe from the terminal side of the coupler where connection from harness side not being possi ble use extra care not to force and cause the male terminal to bend or the female terminal to open Connect the probe as shown to avoid opening of female ter minal Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for locking loose ness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECM VARIOUS SENSORS
40. switch lead wire coupler HO2 sensor circuit open or shorted to ground The heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit C44 P0135 is indicated PAIR control solenoid valve voltage is not input to ECM HO 2 sensor lead wire coupler connection Battery voltage supply to the HO2 sensor PAIR control solenoid valve lead wire coupler VL1500K5 05 MODEL 47 C12 P0335 CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for sec or more Je Metal particles or foreign material being stuck on after receiving the starter signal the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction e ECM malfunction CKP sensor G G Y Q LL Bi Br 9 CKP To Regulator Rectifier GEN INSPECTION Step 1 1 Remove the seats lt 7 Page 121 2 Remove the left and right frame upper covers CC VL1500 Service Manual 6 3 3 Remove the speedometer and fuel inlet cover CC VL1500 Service Manual 6 3 4 Turn the ignition switch OFF 5 Check the CKP sensor coupler for loose or poor contacts If OK then measure the CKP sensor resistance 6 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 178 2420 Green Blue 48 VLI500K5 05 MODEL 7 If OK then chec
41. up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Decomp solenoid operating control 0 4 With the engine starter button pushed click On button At this time if an operation sound is heard from the decomp solenoid valve the function is normal NOTE Decomp solenoid valve can be operated about one second after button is turned On Active control menu PAIR Sol operating control Secondary throttle operating control Decomp sol operating control Quit Fuel injection pulse width for 2 Ignition timing advance for 1 Ignition timing advance for 2 Secondary throttle actuator position sensor Decomp solenoid relay PAIR control solenoid valve Spec select terminal pgiagmiumUmupiliui Test terminal Decomp sol operating control VL1500K5 05 MODEL 65 C19 P0615 STARTER RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Starter relay signal is not input to ECM Starter system circuit open or short ECM malfunction ECM STARTER Engine stop Side stand Ignition RELAY Switch relay Switch 6 STRL Y G OW 0 o pr ac To GP switch STARTER MOTOR INSPECTION Step 1 1 Remove the left frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the Starter relay coupler for
42. voltage at the Red wire and B Br wire 4 Y IAP sensor input voltage 4 5 5 5 V N Red Ground 8 Red B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage 50 VL1500K5 05 MODEL Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal or W Open or short circuit in the Red wire or B Br wire 8 After repairing the trouble clear the DTC using SDS tool CC Page 42 Step 2 1 Connect the IAP sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler Front cylinder side between G B and B Br wires Rear cylinder side between G W and B Br wires IAP sensor output voltage Approx 2 53 V at idle speed Front cylinder side G B B Br Rear cylinder side G W B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Go to Step 3 Check the vacuum hose for crack or damage e Open or short circuit in the G B wire Front cylinder side Open or short circuit in the G W wire Rear cylinder side If vacuum hose and wire are OK replace the IAP sensor with a new one 4 After repairing the trouble clear the DTC using SDS tool CC Page 42 VL1500K
43. 0 2 000 rpm Approx 30 sec FAST IDLE ADJUSTMENT e Remove the seats L7 Page 121 Remove the speedometer and fuel inlet cover frame head covers and frame upper covers VL1500 Service Manual 6 3 Start up the engine and run it in idling condition for warming up Connect a tachometer and set the idle rpm to 1 000 rpm by the throttle stop screw D e Check and adjust the TP sensor C7 Page 36 Turn the ignition switch OFF Disconnect the TP sensor coupler 2 and install the test har ness Start up the engine Measure the TP sensor output voltage at the wire terminals between Red and O Black TP sensor output voltage at idle position Approx 1 12 V 09900 28630 TPS test wire harness 09900 25008 Multi circuit tester set Tester knob indication Voltage Turn the ignition switch OFF e Remove the air cleaner box 103 e Disconnect the STVA coupler Turn the ignition switch ON Open the secondary throttle valve fully by turning it with your finger With the secondary throttle valve held at this position mea sure the output voltage of the TP sensor as shown Calculate the voltage difference between TP sensor output voltage at idle and TP sensor output voltage with the STV full opened Example TP sensor output voltage with the STV fully open Minus TP sensor output voltage at idle is 0 08 V STV fully open 1 20V Idle 1 12V 0 08 V TP se
44. 0 C 176 F Intake air temperature value is fixed to 40 C 104 F VES VES YES YES Ignition signal 1 Ignition off and 1 Fuel cut VES YES 2 cylinder can run 2 Ignition off and 2 Fuel cut VES YES 1 cylinder can run Injection signal 1 Fuel cut VES YES 2 cylinder can run 2 Fuel cut YES YES 1 cylinder can run STV actuator STP sensor Secondary throttle valve is fixed in any position When motor disconnec tion or lock occurs power from ECM is shut off Secondary throttle valve is fixed in any position YES YES YES YES Gear position signal Gear position signal is fixed to 5th gear YES YES HO2 sensor For E 02 19 24 Feedback compensation is inhibited Air fuel ratio is fixed to normal VES YES PAIR control solenoid valve O2 feedback control is stopped and PAIR valve is fixed to open position VES YES The engine can start and can run even if the above signal is not received from each sensor But the engine running condition is not complete providing only emergency help by fail safe circuit In this case it is nec essary to bring the motorcycle to the workshop for complete repair When two ignition signals or two injector signals are not received by ECM the f
45. 00K5 05 MODEL 129 130 VLI500K5 05 MODEL REGULATOR RECTIFIER Remove the secondary gear case cover EC VL1500 Service Manual 3 7 Disconnect the couplers and remove the regulator rectifier Measure the voltage between the terminals using the multi circuit tester as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test 44 o 2 o o ah o o a o a B Black B R Black with Red B W Black with White tracer 1 4 V and more tester s battery voltage NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace the battery of the multi circuit tester B3 VL1500K5 05 MODEL 131 AUTOMATIC DECOMPRESSION SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM Turn signal side stand relay Engine stop switch Fuse 30A IG switch Fuse 15A 2 Automatic decompression relay Neutral indicator light Automatic decom pression solenoid Neutral indicator light switch Clutch lever position switch Starter button Battery Signal generator 132 VL1500K5 05 MODEL SIDE STAND IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper o
46. 4 Page 87 STV actuator Page 74 17 Ignition coil 1 IAP sensor Rear Page 49 2 Regulator rectifier ECM Engine Control Module 03 Generator Fuel pump relay Page 96 CKP sensor Page 47 D Starter relay Main fuse Mode selection switch coupler Side stand switch Ignition switch CHARGING SYSTEM INSPECTION GENERATOR COIL RESISTANCE e Remove the seats Page 121 Remove the speedometer and fuel inlet cover frame head covers and frame upper covers C VL1500 Service Manual 6 3 Disconnect the generator coupler D Measure the resistance among the three lead wires If the resistance is not specified value replace the stator with a new one Also check that the generator core is insulated Generator coil resistance 0 1 1 0 O White White co White Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Q NOTE When making above test it is not necessary to remove the gen erator GENERATOR NO LOAD PERFORMANCE e Disconnect the generator coupler _7 Above Start the engine and keep it running at 5 000 r min Using the multi circuit tester measure the voltage among the three lead wires If the tester reads under the specified value replace the gen erator with a new one Generator no load performance 80 V and more at 5 000 r min When engine is cold 09900 25008 Multi circuit tester set Tester knob indication Voltage VL15
47. 4 04 MODEL For details refer to the chapter 6 of Service Manual e Remove the rear seat CAUTION Be careful not to scratch the rear fender e Remove the seat bracket 2 and front seat SEAT INSTALLATION Installation is in the reverse order of removal Pay attention the following points e With the recessed part D of the rear seat engaged with the tongue of the front seat bracket install the rear seat 122 VL1500K5 05 MODEL FRONT FORK CONSTRUCTION O ring Oil lock piece Front fork spring Inner tube cover guide Damper rod ring Outer tube Rebound Spring Upper inner tube cover Damper rod Rubber Inner tube Washer Slide metal lower inner tube cover Dust seal Inner tube cover stopper Oil seal stopper ring Front fork cap bolt Oil seal Front axle pinch bolt S S e ce eG emo Oil seal retainer oo e eG ee 9e mg Damper rod bolt VL1500K5 05 MODEL 123 REMOVAL AND DISASSEMBLY The front fork removal and disassembly procedures are different from those of the VL1500K4 04 MODEL For details other than the following refer to the VL1500 Service Manual Remove the front wheel front fender and front brake calipers C VL1500 Service Manual 6 7 and 6 12 Loosen the steering stem head nut Loosen the front fork upper clamp bolts left and right NOTE Sl
48. 5 05 MODEL 51 Step 3 1 Turn the ignition switch OFF 2 Remove the IAP sensor c gt Page 118 3 Connect the vacuum pump gauge to the vacuum port of the IAP sensor 4 Arrange 3 new 1 5 V batteries in series check that total voltage is 4 5 5 0 V and connect terminal to the ground terminal and terminal to the Vcc terminal 5 Check the voltage between Vout and ground Also check if voltage reduces when vacuum is applied up to 400 mmHg by using vacuum pump gauge 52 09917 47011 Vacuum pump gauge 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 ECM coupler Harness side Red B Br or G B wire open or shorted to ground or poor or connection Front cylinder side G W Red or B Br wire open or shorted to ground or poor or connection Rear cylinder side If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again If check result is not satisfactory replace the IAP sensor with a new one 6 After repairing the trouble clear the DTC using SDS tool 42 52 VL1500K5 05 MODEL Output voltage Vcc voltage 4 5 5 0 V ambient temp 20 30 C 68 86 F ALTITUDE ATMOSPHER
49. 5010 SUZUKI SUPER GREASE A Others EOT SENSOR REMOVAL Place an oil pan below the EOT sensor e Disconnect the EOT sensor coupler D and remove the EOT sensor 2 Do not remove the EOT sensor when the engine is hot EOT SENSOR REASSEMBLY Install a new gasket washer D Tighten the EOT sensor to the specified torque CAUTION Take special care when handling the temperature sen sor It may cause damage if it gets a sharp impact V EOT sensor 22 N m 2 2 kgf m 16 0 Ib ft 18 11500 5 05 MODEL ENGINE COMPONENTS INSPECTION AND SERVICING CAMSHAFT For details other than the following refer to the VL1500 Service Manual Each camshaft 1 0 code has been changed which is stamped on the camshaft end Front cylinder Rear cylinder code B WEAR height Service Limit IN 35 02 mm 1 379 in 36 58 mm 1 440 09900 20202 Micrometer 25 50 Front cylinder Rear cylinder PRECAUTIONS IN SERVICING When handling the Fl component parts or servicing the Fl sys tem observe the following points for the safety of the system CONNECTOR COUPLER When connecting a connector be sure to push it in until a click is felt With a lock type coupler be sure to release the lock when dis connecting and push in fully to engage the lock when con necting When disconnecting the coupler be
50. 8 C7 VL1500 Service Manual 5 2 Remove the fuel feed hose fuel tank breather hose and fuel drain hose Disconnect the TO sensor coupler D and fuel pump coupler Remove the fuel tank Gasoline is highly flammable and explosive Keep heat spark and flame away VL1500K5 05 MODEL 93 94 11500 5 05 MODEL FUEL PRESSURE INSPECTION e Remove the seats L7 Page 121 Remove the speedometer and fuel inlet cover C VL1500 Service Manual 6 3 Remove the left frame head cover and left frame upper cover C VL1500 Service Manual 6 3 Place a rag under the fuel feed hose Remove the fuel feed hose D Install the special tools between the fuel tank and fuel delivery pipe 09940 40211 Fuel pressure gauge adaptor 09940 40220 Fuel pressure gauge hose attachment 09915 74511 Oil pressure gauge set Turn the ignition switch ON and check the fuel pressure Fuel pressure Approx 300 kPa 3 0 kgf cm 43 psi If the fuel pressure is lower than the specification inspect the following items Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump check valve Pressure regulator Before removing the special tools turn the ignition switch to OFF position and release the fuel pressure slowly Gasoline is highly flammable and explosive Keep heat sparks and flame away
51. 8 Multi circuit tester set Tester knob indication Resistance Q Are the continuity and resistance OK Go to Step 3 Reset the STP sensor position correctly Replace the STP sensor with a new one 8 After repairing the trouble clear the DTC using SDS tool 42 VL1500K5 05 MODEL 81 Step 3 1 Turn the ignition switch OFF 2 Connect the STP sensor coupler 3 Insert the needle pointed probes to the STP sensor coupler 4 Disconnect the STVA lead wire coupler 5 Turn the ignition switch ON 6 Measure the STP sensor output voltage at the coupler between Y W wire and B Br wire by turning the sec ondary throttle valve close and open with a finger STP sensor output voltage Secondary throttle valve is closed Approx 0 5 V Secondary throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 3 ECM coupler Harness side Red Y W or B Br wire open or shorted to ground or poor or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again If check result is not satisfactory replace STP sensor with a ne
52. 95 990 3 7785 3 7791 Measure at 16 mm 0 6 in from the skirt end 95 88 37 7748 Cylinder distortion 0 05 0 002 Piston ring free end gap Approx 13 5 0 53 10 8 0 43 Approx 14 0 0 55 11 2 0 44 VL1500K5 05 MODEL 161 STANDARD LIMIT Piston ring end gap 0 30 0 45 0 012 0 018 0 45 0 60 0 018 0 024 Piston ring to groove clearance Piston ring groove width 1 210 1 230 0 0476 0 0484 1 510 1 530 0 0594 0 0602 2 810 2 830 0 1106 0 1114 Piston ring thickness 1 160 1 175 0 0457 0 0463 1 470 1 490 0 0579 0 0587 Piston pin bore 23 002 23 008 0 9056 0 9058 Piston pin O D 22 992 23 000 0 9052 0 9055 CONROD CRANKSHAFT Unit mm in ITEM STANDARD Conrod small end I D 23 015 23 023 0 9061 0 9064 Conrod big end side clearance 0 10 0 20 0 004 0 008 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 0009 0 0017 Crank pin O D 49 982 50 000 1 9678 1 9685 Crankshaft journal oil clearance 0 020 0 050 0 0008 0 0020 Crankshaft journal O D 51 965 51 980 2 0459 2 0465 Crankshaft journal I D 52 000 52 015 2 0472 2 0478 Crankshaft thrust bearing 1 925
53. AFT CYLINDER HEAD Cam height STANDARD 35 320 35 370 1 3905 1 3925 Unit mm in 36 880 36 930 1 4521 1 4537 Camshaft journal oil clearance 0 032 0 066 IN amp EX 0 0013 0 0026 Camshaft journal holder I D Front head right side rear head left side 20 012 20 025 0 7879 0 7884 Front head left side rear head right side 25 012 25 025 0 9847 0 9852 Camshaft journal O D 19 959 19 980 0 7858 0 7866 Front head right side rear head left side Front head left side rear head right side 24 959 24 980 0 9826 0 9835 Camshaft runout Front amp Rear Rocker arm I D 14 000 14 018 0 5511 0 5519 16 000 16 018 0 6299 0 6303 Rocker arm shaft O D 13 966 13 984 0 5498 0 5506 15 966 15 984 0 6286 0 6293 Cylinder head distortion Cylinder head cover distortion CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in Compression pressure Automatic de compression actuated 1 000 1 400 kPa 10 14 kgf cm 142 199 psi Compression pressure difference 200 kPa 2 kgf cm 28 psi Piston to cylinder clearance 0 02 0 03 0 0008 0 0012 0 120 0 0047 Cylinder bore 96 000 96 015 3 7795 3 7801 Nicks or Scratches Piston diam 95 975
54. Bring the engine rpm to 1 000 r min by the throttle stop screw 2 Check the vacuum of the two cylinders If the adjustment is necessary proceed to the next step NOTE During balancing the throttle valves always set the engine rpm at 1 000 r min using throttle stop screw Step 3 Turn in all the idle air screws to the complete close position Check for difference of vacuum between No 1 and No 2 Equalize these two by gradually turning back the air screw on the higher vacuum side until the vacuum comes down to the lower Check for the synchronization adjustment If the adjustment is not yet correct remove each idle air screw and clean them with a spray type carburetor cleaner and blow dry with a com pressed air Also clean the idle air screw passageways NOTE Slowly turn the idle air screw in clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw can be reset correctly after cleaning After balancing the two valves set the idle rpm to 1 000 r min by the throttle stop screw Step 4 Repeat the above procedure Step 3 until the correct condition USE OF VACUUM BALANCER GAUGE Calibrating each vacuum gauge e Remove the seats lt 7 Page 121 e Remove the speedometer and fuel inlet cover frame head covers and frame upper covers CC VL1500 Service Manual 6 3 Start up the engine and run it in idling condition for warmin
55. ECTOR REMOVAL e Remove the air cleaner box 7 Page 103 With battery negative cable disconnected disconnect the injector couplers Remove the fuel delivery pipe hose and pipes Page 105 e Remove the fuel injectors 1 and 2 105 FUEL INJECTOR INSPECTION Check fuel injector filter for evidence of dirt and contamination If present clean and check for presence of dirt in the fuel lines and fuel tank NOTE The fuel injector can be checked without removing it from the throttle body Refer to page 84 for details FUEL INJECTOR INSTALLATION Apply thin coat of the engine oil to new injector cushion seal and O rings Page 109 Install the injector by pushing it straight to the throttle body Never turn the injector while pushing it Page 109 VL1500K5 05 MODEL 111 112 VL1500K5 05 MODEL FAST IDLE The fast idle system is automatic type When the fast idle cam is turned by the secondary throttle valve actuator the cam pushes the lever on the throttle valve shaft causing the throttle valve to open and raise the engine speed When the engine has warmed up depending on the oil tempera ture ambient temperature and lapsed time the fast idle is can celled allowing the engine to resume idle speed Fast idle cancel ling time 5 C 23 F 1400 2000 rpm Approx 100 sec Ambient Temp Fast idle rpm 15 C 59 F 1 400 2 000 rpm Approx 40 sec 25 C 77 F 1 40
56. Fuel tank Fuel mesh filter For low pressure Fuel filter For high pressure Fuel pump Fuel pressure regulator Before pressurized fuel Fuel injector Pressurized fuel Fuel feed hose Relieved fuel VL1500K5 05 MODEL 29 Fl SYSTEM PARTS LOCATION Speedometer Starter relay Starter motor Intake air pressure sensor 1 IAPS Fuel pump relay FP RELAY Fuel pump Tip over sensor TOS Gear position switch HO2 sensor HO2S For E 02 19 24 Crankshaft position sensor CKPS Fuel injector 2 Fl Fuel injector 1 FI Ignition coil 1 IG COIL Oo 30 11500 5 05 MODEL 0 Sa WS SS SSS S lt Intake air pressure sensor 2 IAPS Decompression solenoid Secondary throttle position sensor STPS Intake air temperature sensor IATS Throttle position sensor TPS Ignition coil 2 IG COIL Secondary throttle valve actuator STVA PAIR solenoid valve Decompression relay Engine oil temperature sensor EOTS VL1500K5 05 MODEL 31 FI SYSTEM WIRING DIAGRAM piousos vc 61 20 3 104 VALS 1o1enioe duooeg ZOH Josues ZOH epoJui i vig 4 2 2 5 5 _ S 4JOJOW JES d 1 soues duooegq QD yous PX 1 puejs epis P 1 d ing
57. IC Reference PRESSURE OUTPUT VOLTAGE mmHg kPa V 760 707 100 94 VL1500K5 05 MODEL 53 C14 P0120 H L TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following TP sensor maladjusted range TP sensor circuit open or short Difference between actual throttle open e TP sensor malfunction ing and opening calculated by is ECM malfunction larger than specified value 0 1 V lt Sensor voltage lt 4 8 V P0120 4 Sensor voltage is higher than specified e TP sensor circuit shorted to VCC or ground circuit value open L Sensor voltage is lower than specified TP sensor circuit open or shorted to ground or value VCC circuit open ECM TP sensor R 8 VCC BI B 0 B Br 2 INSPECTION Step 1 When indicating C14 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then measure the TP sensor input voltage 4 Disconnect the TP sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage at the Red wire B and ground 7 Also measure the voltage at the Red wire and B Br wire TP sensor input voltage 4 5 5 5 V Red Ground amp Red O B Br 09900 25008 Multi circuit tester set Tester knob indication Vo
58. IGNITION IGNITION COIL 1 2 E ri m FRONT TURN SIGNAL LIGHT R oo m o Triuironrou ota 9338555550 88 Hn 5 DECOMP SOLENOID DECOMP RELAY FUEL PUMP FUEL PUMP RELAY w YIG GIR B W Br B WIB Gr B Gr W B W P W B Lg BI R BI Y Gr R B G ECM B BI geese ON BIW BIB BIG Br Y B BIW BUG BUR BUB BIN 1 OW WIR Gr R B W Lg Lg B W B W Gr E3 0 6 HEADLIGHT B w 3 BRAKE LIGHT TAILLIGHT Y B W w FRONT TURN SIGNAL LIGHT L B B B BI B BI B ELEKE Sas 8 sogra Bs d OPTION Ln 850505552855 S98 HORN L HORN cm PASSING DIMMER CLUTCH ee IAT U SWITCH LEVER SE
59. MODEL 83 Is the voltage OK Red wire open or shorted ground FOMI coupler Harness side If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again R B or B G wire open or R B or Red wire shorted to ground Loose or poor contacts on the ECM coupler terminal If wire and connection are OK replace the GP switch with a new one 10 After repairing the trouble clear the DTC using SDS tool Page 42 84 11500 5 05 MODEL C32 P0201 or C33 P0202 FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is Injector circuit open or short interrupted continuous by 4 times or more Injector malfunction ECM malfunction ECM Fuel pump relay To engine stop switch Gr B T Front cylinder Rear cylinder TIT Fuel injector INSPECTION When indicating C32 P0201 for fuel injector 1 When indicating C33 P0202 for fuel injector 2 Step 1 1 Remove the air cleaner box C s Page 103 2 Turn the ignition switch OFF 3 Check the injector coupler Front cylinder side D or Rear cyl inder side for loose or poor contacts If OK then measure the injector resi
60. NSOR LIGHT SWITCH SWITCH POSITION IGNITION SWITCH GP STV ACTUATOR 2 SWITCH SWITCH HANDLEBAR SWITCH L Ledo a i 885 857 IAP i SENSOR SENSOR FRONT REAR EOT PRESSURE SENSOR SWITCH FUSE BOX 1 HEAD HI 2 HEAD LO 3 FUEL 4 IGNITION 15A 5 SIGNAL 15 6 P SOURCE 10A 10A 10A 10A GENERATOR REGULATOR RECTIFIER ON Br B 19 STARTER MOTOR PAIR SOLENOID VALVE 1 MAIN 30 A STARTER RELAY BIW OF swih 12V BATTERY Prepared by SUZUKI MOTOR CORPORATION May 2004 PartNo 99501 39550 01 Printed in Japan SUZUKI MOTOR CORPORATION Printed in Japan 5
61. Other Other OTHERS VL1500K5 05 MODEL 39 MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition D Fair Cloudy Rain Snow D Always Other D Hot O Warm Cool Cold C F Always D Always Sometimes times day month Only once Under condition m LI Weather Temperature Frequency Road Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam O Gravel Other Motorcycle condition Engine condition O Cold Warming up phase Warmed up Always Other at starting D Immediately after start Racing without load Engine speed r min Motorcycle con During driving Constant speed Accelerating Decelerating dition Right hand corner Left hand corner At stop Motorcycle speed when problem occurs km h mile h Other NOTE The above form is a standard sample The form should be modified according to conditions and characteris tics of each market VISUAL INSPECTION Prior to diagnosis using the mode select switch or SDS perform the following visual inspections The rea son for visual inspection is that mechanical fai
62. Others Rear turn signal 1 12V21W Speedometer LED Turn signal indicator light LED Neutral indicator light sess LED High beam indicator light LED Oil pressure indicator light LED FI warning light sasana ane aaa LED CAPACITIES Fuel tank si e ines 14 0 L 3 7 3 1 US Imp gal Engine oil oil change 3 700 ml 3 9 3 3 US Imp qt with filter 4 300 ml 4 5 3 8 US Imp qt OVertiaul iiie fient inni 5 000 ml 5 3 4 4 US Imp qt Final g ar oil cun 200 220 ml 6 8 7 0 7 4 7 7 US Imp oz PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Mileages are expressed in terms of kilome ters miles and time for your convenience NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART VL1500K5 05 MODEL 7 Interval km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500
63. SSIBLE CAUSE Ignition switch signal is not input in the ECM Ignition system circuit open or short ECM malfunction INSPECTION Refer to the IGNITION SWITCH INSPECTION for details lt gt Page 142 VL1500K5 05 MODEL C44 P0130 P0135 HO2 SENSOR HO2S CIRCUIT MALFUNCTION FOR E 02 19 24 DETECTED CONDITION POSSIBLE CAUSE 87 HO2 sensor output voltage is not input HO2 sensor circuit open or shorted to ground to ECM during engine operation and Fuel system malfunction running condition ECM malfunction Sensor voltage x 0 7 V The heater can not operate so that Battery voltage supply to the HO2 sensor heater operation voltage is not supply to the oxygen heater circuit ECM B Br Engine stop Side stand Ignition switch relay switch W G O W e c oN WIB To GP switch id os HO2 sensor TIT INSPECTION Step 1 When indicating C44 P0130 1 Remove the seats lt 7 Page 121 2 Turn the ignition switch OFF 3 Check the HO2 sensor for loose or poor contacts If OK then check the HO2 sensor lead wire continuity 4 Disconnect the HO2 sensor coupler 5 Check the continuity between W G wire and ground 6 Also check the continuity between W G wire and B Br wire B If the sound is not heard from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test 88 11500 5 05 MODEL
64. SUZUKI VL 1500 SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH VL1500 SERVICE MANUAL 99500 39166 01E VL1500K5 05 MODEL 1 VL1500K5 05 MODEL This manual describes service specifications service data and servicing procedures which dif fer from those of the VL1500K4 04 model NOTE e Any differences between the VL1500K4 O4 model and VL1500K5 05 model in specifications and service data are indicated with an asterisk mark Please refer to the VL1500 service manual for details which are not given this manual CONTENTS ABBREVIATIONS USED IN THIS 3 SPECIFICATIONS isissssssaxsnsaskuxkE RI E oia aa wEFERER REX E FER ERFEK XER EFI NENENG 5 PERIODIC MAINTENANCE SCHEDULE e eeeeee eene enean nana nhan tnn nna nn 7 MAINTENANCE AND TUNE UP PROCEDURES 8 ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE 13 ENGINE REMOVAL AND INSTALLATION eene enne 14 ENGINE DISASSEMBLY AND HEASSEMBL Y 9859 naui seein KE RE OCA EVA UR A ARR ER RR ERE RR 17 ENGINE COMPONENTS INSPECTION AND SERVICING 18 PRECAUTIONS IN SERVICING aaaaerennnann nun 19 FI SYSTEM TECHNICAL
65. Since each component is a high precision part great care should be taken not to apply any sharp impacts during removal and installation Be careful not to touch the electrical terminals of the ECM The static electricity from your body may damage this part D Coupler Qo Probe Where male terminal fits INCORRECT When disconnecting and connecting the ECM couplers make sure to turn OFF the ignition switch or electronic parts may get damaged Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the FI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter elec tromotive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a low voltage battery will lead to erroneous diagno sis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnected Otherwise damage to the ECM may result Never connect an ohmmeter to the ECM with its coupler con nected If attempted damage to the ECM or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal
66. VL1500K5 05 MODEL 107 108 VLI500K5 05 MODEL THROTTLE BODY REASSEMBLY Reassemble the throttle body in the reverse order of disassem bly Pay attention to the following points e With the STV fully open install the STP sensor and tighten the STP sensor mounting screw to the specified torque NOTE Apply thin coat of the engine oil to the new O ring Align the secondary throttle shaft end with the groove B of STP sensor Apply SUZUKI SUPER GREASE A to the secondary throttle shaft end if necessary MAH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 09930 11950 Torx wrench V STP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft NOTE Make sure the STP valve open or close smoothly If the STP sensor adjustment is necessary refer to page 110 for STP sensor setting procedure With the throttle valve fully closed install the TP sensor 2 and tighten the TP sensor mounting screw to the specified torque NOTE Apply thin coat of the engine oil to the new O ring Align the throttle shaft end with the groove of TP sensor Apply SUZUKI SUPER GREASE A to the throttle shaft end if necessary AGH 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others 09930 11950 Torx wrench V TP sensor mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft NOTE Make sure the throttle valve open o
67. Y or AREA EFFECTIVE FRAME NO U S A Except for California JS1VY52A 52100001 EU JS1AL211100105237 Australia JS1AL211300100688 Canada JS1VY52A 52100001 California U S A JS1VY52A 52100001 VL1500K5 05 MODEL 3 ABBREVIATIONS USED IN THIS A F BBDC BTDC B C CKP Sensor CKT CLP Switch CO CPU D DC DMC DOHC DRL APS Air Fuel Mixture Before Bottom Dead Center Before Top Dead Center Battery Positive Voltage Crankshaft Position Sensor CKPS Circuit Clutch Lever Position Switch Clutch Switch Carbon Monoxide Central Processing Unit Direct Current Dealer Mode Coupler Double Over Head Camshaft Daytime Running Light EVAP Canister FI EP FPR FP Relay G GEN GND GP Switch H HC HO2 Sensor IAP Sensor IAT Sensor IG LCD LED LH MANUAL A E ABDC After Bottom Dead Center ECM Engine Control Module AC Alternating Current Engine Control Unit ECU ACL Air Cleaner Air Cleaner Box FI Control Unit API American Petroleum Institute EOT Sensor Engine Oil Temperature ATDC After Top Dead Center Sensor EOTS Oil Temp ATM Pressure Atmospheric Pressure Sensor Atmospheric Pressure Sensor EVAP Evaporative Emission Evaporative Emission Canister Canister Fuel Injection Fuel Injector Fuel Pump Fuel Pressure Regulator Fuel Pump Relay Generator Ground Gear Position Switch
68. a new one CAUTION Take special care when handling the EOT sensor It may cause damage if it gets a sharp impact Do not contact the EOT sensor and the column ther mometer with a pan VL1500K5 05 MODEL 63 C18 P1751 DECOMP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Decomp relay signal is not input to ECM Decomp system circuit open or short ECM malfunction ECM Engine stop Side stand Ignition Decomp relay Switch relay Switch DRL G R 00 Decomp solenoid TIT INSPECTION Step 1 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the Decomp relay coupler for loose or poor contacts If OK then check the Decomp relay Refer to VL1500 Service Manual 7 20 for details Is the Decomp relay OK ECM coupler Harness side O W or G R wire open or shorted to ground or poor 49 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the Decomp relay with a new one 4 After repairing the trouble clear the DTC using SDS tool C Page 42 64 11500 5 05 MODEL ACTIVE CONTROL INSPECTION 1 Set
69. ace the combination meter with a new one after checking connection of couplers 000 _ TRIPS SPEEDOMETER If the speedometer odometer or trip meter does not function properly inspect the speedometer sensor and connection of coupler If the speedometer sensor and connection are all right replace the meter with a new one SPEEDOMETER SENSOR Remove the right frame cover 7 VL1500 Service Manual 6 2 Remove the rear clutch cover C VL1500 Service Manual 3 6 Disconnect the speed sensor lead wire coupler 1 Remove the speedometer sensor by removing its mounting bolt e Connect 12 V battery 10 kQ resistor and the multi circuit tester as shown in the right illustration R B Red with Black tracer B W Black with White tracer P Pink 09900 25008 Multi circuit tester set Tester knob indication Voltage Under above condition if a suitable screwdriver touching the pick up surface of the speedometer sensor is moved the tester voltage reading should change 0 V gt 12 V or 12 V gt If the tester voltage reading does not change replace the speedometer sensor with a new one NOTE The highest voltage reading in this test will be the same as that of battery voltage RELAYS FUEL PUMP RELAY C3 Page 96 VL1500K5 05 MODEL 141 Battery voltage 142 VL1500K5 05 MODEL SWITCHES inspect each switch for con
70. ail safe circuit can not work and ignition or injection is stopped 38 11500 5 05 MODEL FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis EXAMPLE CUSTOMER PROBLEM INSPECTION FORM User name Model Date of issue Date Reg Date of problem Malfunction indicator lamp condition LED Malfunction display code User mode No display Malfunction display LCD Dealer mode No code Malfunction code Always ON Sometimes ON Always OFF Good condition PROBLEM SYMPTOMS D Difficult Starting O Poor Driveability No cranking D Hesitation on acceleration O No initial combustion D Back fire L After fire No combustion D Lack of power D Poor starting at O Surging cold warm always Abnormal knocking O Other D Engine rpm jumps briefly Other O Poor Idling Engine Stall when Poor fast idle D Immediately after start Abnormal idling speed O Throttle valve is opened 5 High Low r min O Throttle valve is closed Unstable D Load is applied Hunting r min to r min
71. atching mark White Cushion seat Apply an adhesive agent to the cushion seat Wiring harness VL1500K5 05 MODEL 153 EXTERIOR PARTS INSTALLATION METER FUEL INLET COVER INSTALLATION Fuel lid hinge bracket Frame upper cover L 5 Frame upper cover R Fuel lid D 1 2 Speedometer Fuel inlet cover Fuel lid cover Speedometer switch cover Outside Apply an adhesive agent amp emeo 154 VL1500K5 05 MODEL FRAME UPPER COVER INSTALLATION D Cushion seat Molding Apply an adhesive agent Bend up the stay Cushion rubber 50 mm 2 0 in VL1500K5 05 MODEL 155 FRAME HEAD COVER INSTALLATION D Cushion seat 3 mm 0 12 in Apply an adhesive agent 156 VLI500K5 05 MODEL GREASE UP POINTS 5 0 kgf m 36 0 lb ft H Brake pedal height 98 mm 3 86 in x Apply an adhesive agent SPECIAL TOOLS 09900 25009 Needle pointed probe set 09900 28630 TPS test wire har ness 09904 41010 SDS set tool VL1 09904 41030 004 CD ROM Ver 4 09940 40211 Fuel pressure gauge adapter NOTE 09940 40220 Fuel pressure gauge hose attachment 09930 11950 Torx wrench 09930 82720 Mode selection switch When order the special tool please confirm whether it is available or not 500K5
72. ause of this indication is as follows Engine stop switch is in OFF position Side stand ignition inter lock system is not working Ignition fuse is burnt NOTE Until starting the engine the FI light turns ON The FI light is also turned ON when engine temperature is high or oil pressure is low 34 11500 5 05 MODEL DEALER MODE The defective function is memorized in the computer Use the special tool s coupler to connect to the dealer mode coupler The memorized malfunction code is displayed on the LCD DISPLAY panel Malfunction means that the ECM does not receive signal from the devices These affected devices are indicated in the code form 09930 82720 Mode select switch CAUTION Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the ECM are disconnected the malfunction code memory is erased and the malfunction code can not be checked LCD DISPLAY Fl LIGHT INDICATION INDICATION NO Coo code is indicated MALFUNCTION INDICATION MODE FI light turns OFF For each 2 sec ES from small numeral to large one code is indicated VL1500K5 05 MODEL 35 CODE MALFUNCTION PART REMARKS COO None No defective part C12 Crankshaft position sensor CKPS Pick up coil signal signal generator C13 Intake air pressure sensor 2 IAPS 2 For Front cylinder C14 Throttle position sensor
73. ckness 5 30 5 40 0 209 0 213 Damper spring free length Gearshift lever height 82 3 23 Secondary bevel gear backlash 0 03 0 15 0 001 0 006 Final bevel gear backlash 0 03 0 64 0 001 0 025 VL1500K5 05 MODEL 163 INJECTOR FUEL PUMP FUEL PRESSURE REGURATOR ITEM SPECIFICATION Injector resistance Approx 11 7 at 20 C 68 F Fuel pump discharge amount 168 ml 5 7 5 9 US Imp oz and more 10 sec Fuel pressure regulator operat ing set pressure Approx 300 kPa 3 0 kgf cm 43 psi FI SENSORS ITEM SPECIFICATION CKP sensor resistance 178 242 CKP sensor peak voltage 2 4 V and more When cranking IAP sensor input voltage 45 5 5V IAP sensor output voltage Approx 2 53 V at idle speed TP sensor input voltage 45 5 5V TP sensor resistance Closed Approx 4 66 kQ Approx 1 12 kQ Opened Approx 4 41 kQ TP sensor output voltage Closed Approx 1 12 V Opened Approx 4 41 V EOT sensor input voltage 45 5 5V EOT sensor output voltage 0 1 4 6 V EOT sensor resistance Approx 61 3 KQ at 20 C 68 F IAT sensor input voltage 4 5 5 5V IAT sensor output voltage 0 1 4 6 V IAT sensor resistance Approx 2 45 KQ at 20 C 68 F TO sensor resistance 19 1 19 7 KQ TO sensor voltage Nor
74. d to VCC or ground circuit open Sensor voltage is lower than specified value STP sensor circuit open or shorted to ground or VCC circuit open C32 C33 P0201 P0202 46 VL1500K5 05 MODEL DETECTED ITEM Gear posi tion signal Fuel injector Fuel pump relay Ignition switch HO2 sensor For E 02 19 24 PAIR control solenoid valve DETECTED FAILURE CONDITION Gear position signal voltage should be higher than the following for 3 seconds and more Gear position sensor voltage 0 6 V If lower than the above value C31 P0705 is indicated CKP sensor pickup coil signal is pro duced but fuel injector signal is inter rupted 4 times or more continuously In this case the code C32 P0201 or C33 P0202 is indicated No voltage is applied to the fuel pump although fuel pump relay is turned ON or voltage is applied to fuel pump although fuel pump relay is turned OFF Ignition switch signal is not input to ECM HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage lt 0 1 V In other than the above value C44 P0130 is indicated CHECK FOR GP switch lead wire coupler connection gearshift cam etc Fuel injector wiring coupler con nection power supply to the injector Fuel pump relay lead wire cou pler connection power source to the fuel pump relay and fuel injectors Ignition
75. e master cylinder mounting bolt Front brake caliper mounting bolt Front brake caliper housing bolt Brake hose union bolt Front brake hose joint nut Front brake hose adaptor Air bleeder valve Handlebar set bolt Handlebar holder nut Front footrest bolt Rear brake master cylinder rod lock nut Rear brake pedal bolt Rear brake master cylinder mounting bolt Clutch hose union bolt Clutch master cylinder mounting bolt Rear swingarm pivot bolt Left Rear swingarm pivot bolt Right Rear swingarm pivot lock nut Rear shock absorber mounting nut Upper and Lower Rear cushion lever rod mounting nut Rear axle nut Rear caliper mounting bracket bolt nut Rear brake caliper mounting bolt Rear brake caliper housing bolt Final gear case mounting nut NOTE Item marked with asterisk is exclusive to VL1500K5 O5 MODEL Refer to page 126 for the and tightening VL1500K5 05 MODEL 13 ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame Refer to the page listed in each section for removal and reinstallation instructions ENGINE LEFT SIDE Secondary case Secondary driven bevel gear Gear position switch body Clutch release cylinder Starter torque limiter Starter idle gear Starter clutch Gearshift lever and linkage Gene
76. e switch V 14 Nm 1 4 kgf m 10 0 Ib ft tm S 160 N m AB 16 0 kgf m EC 115 5 lb ft ANA Gear position switch V 11 Nm Regulator rectifier 1 1 kgf m 8 0 Ib ft VL1500K5 05 MODEL 145 Clutch hose Clamp High tension cord Frame A N Clamp PS re Set the clamp between the Wiring harness Wiring harness sensor For E 02 19 24 IAP sensor and horn bracket j j IAM aan A vj NS N b LE 2 2 2 gt 27 2 ZEE I 4 NT 2 6 Generator coupler amp 0 Wiring harness Don t set lead wire on pipe Except TO sensor Cl Pass through the high tension cord inside of the breather hose B ee coil TO sensor x Set the UP mark to the top Brake hose IAP sensor Decomp relay ES Plate approval mark Except for E 03 24 28 33 Horn For E 02 19 J Fuse box Turn signal side stand relay Stop lamp switch 2 careful contact the Stop lamp switch d wire harness to the clutch cover Battery A OIL pressure switch Clamp Frame Stop lamp switch 146 VL1500K5 05 MODEL Clamp Handle switch R L Clamp Brake hose Clutch hose Boots Clamp Wiring harness Front turn R L Handle switch R L Clamp Horn lead wire For E 03 24 28 33 Horn
77. e the ECM with a known good one and inspect it again Loose or poor contacts on the ECM coupler Replace the STVA with a new one 5 After repairing the trouble clear the DTC using SDS tool Page 42 VL1500K5 05 MODEL 75 76 VL1500K5 05 MODEL ACTIVE CONTROL INSPECTION 1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Turn the ignition switch ON 3 Click Secondary throttle operating control Secondary throttle operating control Active control menu PAIR Sol operating control Decomp sol operating control Quit 4 Click each button 0 At this time if an operation sound is heard from the STVA the function is normal Ignition timing advance for 2 99 1 Ga Secondary throttle operating control Secondary throttle actuator position sensor 949 X 7 Decomp solenoid relay Off PAIR control solenoid valve Full closed Secondary throttle full opened Except full opn Secondary throttle full closed Except full cls Full opened Spec select terminal GND 00 00 000 0 Test terminal Open VL1500K5 05 MODEL 77 C29 P1654 H L STP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C29 Signal voltage is not within the following STP sensor maladjusted range STP sensor circuit open or short Difference between actual thr
78. e within one ball dia If the difference is larger than one ball turn the idle air screw on the throttle body and bring the ball to the same level A correctly adjusted throttle valve synchronization has the balls in the No 1 and No 2 at the same level 09913 13121 Vacuum balancer gauge NOTE During balancing the throttle valves always set the engine rpm at 1 000 r min using throttle stop screw After balancing the four valves set the idle rpm to 1 000 r min by the throttle stop screw THROTTLE POSITION SENSOR TPS SETTING After all adjustments are completed check or adjust the TPS setting condition Page 36 VL1500K5 05 MODEL 117 118 VL1500K5 05 MODEL SENSORS IAP SENSOR INSPECTION The intake air pressure sensor is located at the rear side of the air cleaner box Page 49 IAP SENSOR REMOVAL INSTALLATION Remove the frame head covers and frame upper covers VL1500 Service Manual 6 3 e Remove the IAP sensors and disconnect the couplers and vacuum hoses 3 Installation is in the reverse order of removal TP SENSOR INSPECTION The throttle position sensor is installed on the No 2 throttle body Page 53 TP SENSOR REMOVAL INSTALLATION Remove the right frame head cover and right frame upper cover C s VL1500 Service Manual 6 3 Remove the TP sensor and disconnect the coupler 1 09930 11950 Torx wrench Install the TP sensor to the No 2 throttle body
79. eaning the motorcycle 5 Dismount the TO sensor from its bracket and measure the voltage when it is leaned 65 and more left and right from the horizontal level TO sensor voltage Leaning 3 7 4 4 V Br W 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Red Br W or B Br wire open or shorted to ground or poor or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Loose or poor contacts on the ECM coupler Open or short circuit Replace the TO sensor with a new one 6 After repairing the trouble clear the DTC using SDS tool Page 42 VL1500K5 05 MODEL 73 C24 P0351 or C25 P0352 IGNITION SYSTEM MALFUNCTION When indicating C24 P0351 for IG coil 1 When indicating C25 P0352 for IG coil 2 Refer to the IGNITION SYSTEM for details C 7 Page 133 74 VL1500K5 05 MODEL C28 P1655 STV ACTUATOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The operation voltage does not reach the STVA STVA malfunction ECM does not receive communication signal from STVA circuit open or short the STVA STVA motor malfunct
80. eck the STP sensor lead wire continuity 4 Disconnect the STP sensor coupler 5 Check the continuity between Y W wire B and Red wire A If the sound is not heard from the tester the circuit condition is OK 6 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 7 Check the continuity between wire B and terminal 4 8 Also check the continuity between B Br wire and terminal 4 STPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK YES Go to Step 2 NO Y W wire shorted to VCC or B Br wire open 9 After repairing the trouble clear the DTC using SDS tool CC Page 42 ECM coupler Harness side VL1500K5 05 MODEL 79 Step 1 When indicating P1654 L 1 Remove the air cleaner box 2 Page 103 2 Turn the ignition switch OFF 3 Check the STP sensor coupler for loose or poor contacts If OK then check the STP sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between Y W wire and ground 6 Also check the continuity between Y W wire and B Br wire If the sound is not heard from the tester the circuit condi tion is OK 7 Remove the left frame upper cover C gt VL1500 Service 1
81. er 8 comes out from the fuel tank Set the fuel pump mounting plate to the horizontal line Turn the fuel pump mounting plate counterclockwise to approx 90 Pull the fuel pump mounting plate until the fuel pump band 9 comes out from the fuel tank Remove the fuel pump assembly CAUTION Be careful not to bend the fuel level gauge VL1500K5 05 MODEL 99 FUEL PUMP DISASSEMBLY CONSTRUCTION va 609 ome Fuel pump holder V ITEM N m kgf m Ib ft 1 0 7 0 D Band Fuel pump O ring 3 Rubber cushion Fuel pump mounting bolt 10 100 VLI500K5 05 MODEL DISASSEMBLY Remove the fuel pump holder D e Disconnect the fuel pump coupler Remove the band rubber cushion and fuel pump FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result Blow the fuel mesh filter with compressed air NOTE If the fuel mesh filter is clogged with many sediment or rust replace the fuel filter cartridge with a new one REASSEMBLY Reassembly the fuel pump in the reverse order of disassem bly and pay attention to the following points Apply thin coat of engine oil to the new bushing and install it to the fuel joint pipe CAUTION Use the new bushing to prevent fuel leakage
82. ew vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removing or puncturing the muffler baffles header pipes screen type spark arrester if equipped or any other component which conducts exhaust gases Removing or puncturing the air cleaner case air cleaner cover baffles or any other component which conducts intake air Replacing the exhaust system or muffler with a system or muffler not marked with the same model spe cific code as the code listed on the Motorcycle Noise Emission Control Information label 172 VL1500K5 05 MODEL PAIR AIR SUPPLY SYSTEM INSPECTION HOSES AND PIPES e Remove the PAIR cover C s Page 14 Inspect the hoses for wear or damage Inspect that the hoses for secure connection PAIR REED VALVE e Remove the PAIR control solenoid valve C s Page 14 e Remove the reed valve case D and PAIR reed valve Inspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one e Install the reed valve and its case with outlet pipes the facing the PAIR control solenoid valve D PAIR CONTROL SOLENOID VALVE e Remove the PAIR control solenoid va
83. g MTBE Methyl Tertiary Butyl Ether less than 1096 etha nol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended E 03 28 33 The others OL 3 7 3 1 US Imp gal SAE 10W 40 API SF or SG 3 700 ml 3 9 3 3 US Imp qt 4 300 ml 4 5 3 8 US Imp qt 5 000 ml 5 3 4 4 US Imp qt SUZUKI FORK OIL SS 08 10 or equivalent fork oil Fuel tank Engine oil type Engine oil capacity Change Filter change Overhaul Front fork oil type VL1500K5 05 MODEL 167 STANDARD Front fork oil capacity each leg 6 ml 14 1 14 6 US Imp oz Bevel gear oil type Bevel gear oil capacity Hypoid Gear oil 90 API GL 5 200 220 ml 6 8 7 0 7 4 7 7 US Imp oz Brake fluid type DOT 4 168 VLI500K5 05 MODEL EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM VL1500K5 motorcycles are equipped with a fuel injection system for emission level control This fuel injection system is precision designed manufactured and adjusted to comply with the applicable emission limits Fuel tank Fuel mesh filter For low pressure Fuel filter For high pressure Fuel pump Fuel pressure regulator Before pressurized fuel Fuel delivery pipe Pressurized fuel Fuel injector Relieved fuel Fuel feed hose
84. g up Stop the warmed up engine e Disconnect the IAP sensor couplers Page 49 e Disconnect the IAP sensor vacuum hose 0 from the No 1 throttle body VL1500K5 05 MODEL 115 116 VL1500K5 05 MODEL Connect one of the vacuum balancer gauge hose Q to the vacuum nipple on the No 1 throttle body 09913 13121 Vacuum balancer gauge Connect a tachometer Start up the engine and keep it running at 1 000 r min by turn ing throttle stop screw 3 09900 25008 Multi circuit tester set Turn the air screw of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball in the tube to the center line 6 NOTE The vacuum gauge is positioned approx 45 from the horizontal level After making sure that the steel ball stays steady at the center line disconnect the hose from the No 1 throttle body vacuum nipple and connect the next hose to this vacuum nipple Turn air screw to bring the other steel ball D to the center line The balancer gauge is now ready for use in balancing the throt tle valves Throttle valve synchronization Using the vacuum balancer gauge inspect the throttle valve synchronization in the same manner as the digital vacuum tester Pay attention to the following points The vacuum gauge is positioned approx 45 from the horizontal level and in this position the two balls should b
85. ge 135 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK YES Go to Step 4 NO Go to Step 5 Step 4 1 Check the plug caps for poor contacts 2 If OK then inspect the spark plugs C7 VL1500 Service Manual 2 4 Are the spark plugs OK YES Go to Step 5 NO Faulty spark plug s Step 5 1 Inspect the ignition coils 136 Are the ignition coils OK YES Go to Step 6 NO Faulty ignition coil s Step 6 1 Measure the CKP sensor peak voltage and its resistance _ gt Page 136 and 137 NOTE The CKP peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Are the peak voltage and its resistance OK Faulty ECM Open or short circuit in wire harness Poor connection of ignition couplers Faulty CKP sensor Metal particles or foreign material being stuck on the CKP sensor and rotor tip INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the frame head covers and frame upper covers C VL1500 Service Manual 6 3 Remove the cylinder head side caps and disconnect the spark plug caps VL1500 Service Manual 3 8 Connect new spark plugs to each spark plug cap and ground them to the cylinder head NOTE Make sure that all couplers and spark plugs are connected prop erly and the battery used is in fully charged condition Measure the 1 and 2 ignition co
86. height LAICUS 700 mm 27 6 in DIV MASS idc EE iE Ee Ry 302 kg 665 lbs ENGINE E ELI 4 stroke Air cooled OHC Number of cylinders 2 ljlc EA 96 mm 3 780 in Stoke dedere de didis 101 mm 3 976 in Displacement 1 462 89 2 cu in Compression ratio 8 5 1 FUCISYSIOM feiss io de teet ee Fuel injection Air cleatier c oe Oe ADU Non woven fabric element Start r syst mo oa c o Hed anu Electric Lubrication system Wet sump Idle Speed ae a gana aa 1000 100 r min DRIVE TRAIN AMAN Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Primary reduction ratio 1 490 76 51 Secondary reduction ratio 0 852 29 34 Gear ratios Low 3 000 36 12 2 NAK 1 823 31 17 HS NG NANG 1 333 28 21 AU RP 1 041 25 24 HOP aaa ag 0 884 23 26 Final reduction 2 666 19 19 x 32 12 Drive System uir EE Silene itis Shaft drive 6 11500 5 05 MODEL CHASSIS Front suspension eseese Telescopic spring oil damped Rear
87. ice Manual 3 8 Measure the ignition coil resistance in both the primary and secondary windings If the resistance is not within the stan dard range replace the ignition coil with a new one Ignition coil resistance Primary 1 7 terminal terminal Secondary 18 28 Plug cap terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance CKP SENSOR PEAK VOLTAGE e Remove the seats L gt Page 121 Remove the speedometer and fuel inlet cover frame head covers and frame upper covers VL1500 Service Manual 6 3 NOTE Make sure that all of the couplers are connected properly and the battery used is in fully charged condition Measure the CKP sensor peak voltage in the following proce dures Disconnect the CKP sensor lead wire coupler 0 Connect the multi circuit tester with the peak volt adaptor as follows Probe Green lead wire Probe Blue lead wire CAUTION Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual CKP sensor coupler 15 sensor VL1500K5 05 MODEL 137 Shift the transmission into the neutral and turn ignition switch ON Crank the engine a few seconds with the starter motor by depressing starter button and check the CKP sensor peak voltage Repeat the above procedure a few times and measure
88. ightly loosen the front fork cap bolts 3 before loosening the lower clamp bolts to facilitate later disassembly Loosen the front lower clamp bolts left and right NOTE Hold the front fork by the hand to prevent it from falling down e Remove the front forks left and right e Remove the upper inner tube covers 5 washers and rub bers left and right e Remove the front fork lower inner tube cover washer D and rubber 8 124 VL1500K5 05 MODEL Remove the front fork cap bolts 7 INSPECTION For details other than the following refer to the VL1500 Service Manual FORK SPRING Front fork spring free length Service Limit 589 mm 23 2 in REASSEMBLY AND REMOUNTING The front fork reassembly and remounting procedures are differ ent from those of the VL1500K4 04 MODEL For details other than the following refer to the VL1500 Service Manual FORK OIL Capacity each leg 416 ml 14 1 14 6 US Imp oz Fork oil level 192 mm 7 56 in 09943 74111 Front fork oil level gauge VL1500K5 05 MODEL 125 Install the front fork cap bolt e Install the inner tube cover stopper at 284 3 mm 11 19 in from the upper surface of the inner tube Set the washer and rubber 3 to the inner tube e Install the upper inner tube cover NOTE When installing the front fork inner tube upper cover align the hole O in the front fork inne
89. ils primary peak voltage in the following procedure Connect the multi circuit tester with peak voltage adaptor as follows 1 ignition coil Probe White terminal Probe Ground 2 ignition coil Probe Black Yellow terminal C Probe Ground NOTE Do not disconnect the ignition coil primary wire coupler 09900 25008 Multi circuit tester set CAUTION Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual Shift the transmission into neutral and turn ignition switch ON Crank the engine a few seconds with the starter motor by depressing starter button and check the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage If the peak voltage is lower than the specified values inspect the ignition coil Ignition coil primary peak voltage 180 V and more Tester knob indication Voltage Avoid touching the tester probes and spark plugs to prevent an electric shock while testing VL1500K5 05 MODEL 135 gt ER Ignition coil W or B Y New spark ECM plug T Battery 136 VLI500K5 05 MODEL IGNITION COIL RESISTANCE e Remove the frame head covers and frame upper covers VL1500 Service Manual 6 3 e Remove the cylinder head side caps and disconnect the spark plug caps C7 VLI500 Serv
90. in ECM memory can be checked by the SDS Be sure to read PRECAUTIONS IN SERVICING F Page 19 before inspection and observe what is written there Remove the left side frame head cover C VL1500 Service Manual 6 3 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code and show data when trouble displaying data at the time of DTC according to instructions displayed on SDS Not only is SDS used for detecting Diagnostic Trouble Codes but also for reproducing and checking on screen the failure condition as described by customers using the trigger How to use trigger Refer to the SDS operation manual for further details 09904 41010 SDS set tool 09904 41030 004 CD ROM Ver 4 9 Se 42 VL1500K5 05 MODEL USE OF SDS DIAGNOSIS RESET PROCE DURE After repairing the trouble turn OFF the ignition switch and turn ON again e Click the DTC inspection button D Check the DTC The previous malfunction history code Past DTC still remains stored in the ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS e Click Clear to delete history code Pas
91. ion ECM B Lg 5 STVA 1B P W 87 STVA 1A G STVA 2B W B STVA 2A INSPECTION Step 1 1 Remove the air cleaner box Page 103 2 Turn the ignition switch OFF 3 Check the STVA lead wire coupler for loose or poor contacts 4 Turn the ignition switch ON to check the STV operation STV operating order 95 open Full open 95 open Is the operating OK Go to Step 2 Loose or poor contacts on the STVA coupler Open or short circuit in the B Lg P W W B or Green wires f wire and connection are OK go to Step 2 5 After repairing the trouble clear the DTC using SDS tool 42 Step 2 1 Turn the ignition switch OFF 2 Disconnect the STVA lead wire coupler 3 Check the continuity between each terminal and ground STVA continuity co Q Infinity Terminal Ground 4 If OK then measure the STVA resistance between Black wire and Pink wire B and between Green wire and W B wire D STVA resistance Approx 6 5 Black Pink B Green W B 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK B Lg P W Green and W B wire open or shorted to ground or poor 65 87 44 and connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replac
92. ion is in the reverse order of removal V EOT sensor 22 N m 2 2 kgf m 16 0 Ib ft 120 VL1500K5 05 MODEL TO SENSOR INSPECTION The tip over sensor is located under the front seat CC Page 70 TO SENSOR REMOVAL INSTALLATION e Remove the seats Page 121 Disconnect the coupler and remove the TO sensor Installation is in the reverse order of removal NOTE When installing the TO sensor bring the UPPER letter on it to the top HO2 SENSOR INSPECTION FOR E 02 19 24 The heated oxygen sensor is installed on the pre muffler 87 HO2 SENSOR REMOVAL INSTALLATION Remove the seats C 7 Page 121 e Disconnect the coupler D and remove the HO2 sensor unit Do not remove the HO2 sensor while it is hot CAUTION Be careful not to expose it to excessive shock Do not use an impact wrench while removing or installing the HO2 sensor unit Be careful not to twist or damage the sensor lead wire e Installation is in the reverse order of removal CAUTION Do not apply oil or other materials to the sensor air hole Tighten the sensor unit to the specified torque V HO2 SENSOR 25 N m 2 5 kgf m 18 0 Ib ft Route the HO2 sensor lead wire properly CC Page 145 and 146 VL1500K5 05 MODEL 121 EKTERIOR PARTS SEAT REMOVAL This section gives only parts removal procedure which differ from that of the VL1500K
93. k the continuity between each terminal and ground CKP sensor continuity Q Infinity Blue Ground Green Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK YES Go to step 2 NO Replace the CKP sensor with a new one 8 After repairing the trouble clear the DTC using SDS tool 42 Step 2 1 Crank the engine a few seconds with the starter motor and measure the CKP sensor peak voltage at the coupler 2 Repeat the above test procedure a few times and measure the highest peak voltage CKP sensor peak voltage 2 4 V and more Green Blue D Peak volt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 2 ECM coupler Harness side G Y or Brown wire open or shorted to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal or If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip If there are no metal particles and foreign mate rial then replace the CKP sensor with a new one 3 Afte
94. l injector VM CKP sensor signal CKP Power source B 1 Power source for back up B 2 Blank ECM ground E1 Blank Sensors ground E2 Serial data for speedometer TECH Serial data for self diagnosis SDL D 9 D TERMINAL NO CIRCUIT STVA signal STVA 1B S 8 S S SSIS S 66 TERMINAL NO CIRCUIT STVA signal STVA 2B HO2 sensor heater HO2 For E 02 19 24 S Fuel pump relay FP Relay STVA signal STVA 1A STVA signal STVA 2A Blank PAIR control solenoid valve PAIR Ground E01 Ground E02 Rear cylinder Fuel injector 1 Decomp solenoid DRL Front cylinder Fuel injector 2 Starter relay STR Blank Blank oso S Front cylinder Ignition coil G2 8 S eee Rear cylinder Ignition coil IG1 VL1500K5 05 MODEL 33 SELF DIAGNOSIS FUNCTION The self diagnosis function is incorporated in the ECM The function has two modes User mode and Dealer mode The user can only be notified by the LCD DISPLAY panel and LED FI light To check the function of the individual Fl system devices the dealer mode is prepared In this check the special tool is necessary to read the code of the malfunction items USER MODE FI LIGHT INDICATION LCD DISPLAY INDICATION NO Odometer 1 MALFUNCTION INDICATION MODE
95. le clear the DTC using SDS tool C Page 42 86 11500 5 05 MODEL C41 P0230 FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although fuel Fuel pump relay circuit open or short pump relay is turned ON or voltage is applied to fuel Fuel pump relay malfunction pump although fuel pump relay is turned OFF ECM malfunction ECM CUN CS Fuel pump Engine stop Switch o IV po ot oN To GP Ignition oe VM Y R oT R W switch _ Side stand switch FP Relay Y 00 4 0o w relay Fuel pump relay INSPECTION Step 1 1 Remove the right frame upper cover VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the FP relay coupler for loose or poor contacts If OK then check the FP relay Refer to page 96 for details Is the FP relay OK Yellow or O W wire open or shorted to ground or poor 49 connection Y R or RAW wire open or poor 40 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the FP relay with a new one 4 After repairing the trouble clear the DTC using SDS tool C 7 Page 42 C42 P01650 IG SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION PO
96. loose or poor contacts If OK then inspection the Starter relay Refer to VL1500 Service Manual 7 17 for details Is the Starter relay OK O W and Y G wire open or shorted to ground or poor GD connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the Starter relay with a new one 4 After repairing the trouble clear the DTC using SDS tool C Page 42 66 VL1500K5 05 MODEL C21 P0110 H L IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE C21 Output voltage is not within the following IAT sensor circuit open or short range AT sensor malfunction 0 1 x Sensor voltage 4 6 V ECM malfunction P0110 H Sensor voltage is higher than specified je IAT sensor circuit open or ground circuit open value L Sensor voltage is lower than specified IAT sensor circuit shorted to ground value IAT sensor EGM N Dg 2 IAT 2 INSPECTION Step 1 When indicating C21 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the IAT sensor coupler for loose or poor contacts If OK then measure the IAT sensor voltage at the wire side coupler 4 Disconnect the IAT sen
97. ltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal or W Open or short circuit in the Red wire or B Br wire 54 VL1500K5 05 MODEL Step 1 When indicating P0120 H 1 Remove the right frame upper cover VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between BI B wire and Red wire If the sound is not heard from the tester the circuit condition is OK 6 Remove the left frame upper cover C gt VL1500 Service Manual 6 3 and disconnect the ECM coupler 7 Check the continuity between BI B wire W and terminal Q9 8 Also check the continuity between B Br wire O and terminal 4 TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK YES Go to Step 2 NO BI B wire shorted to VCC or B Br wire open 9 After repairing the trouble clear the DTC using SDS tool 42 ECM coupler Harness side VL1500K5 05 MODEL 55 Step 1 When indicating P0120 L 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn
98. lures such as oil leakage cannot be displayed on the screen with the use of mode select switch or SDS Engine oil level and leakage C 5 VL1500 Service Manual 2 6 Fuel level and leakage Page 8 Clogged air cleaner element VL1500 Service Manual 2 4 Battery condition C 7 VL1500 Service Manual 7 36 Throttle cable play Page 9 Vacuum hoses looseness bend and disconnection Broken fuse FI light operation C gt Page 33 and 140 Each warning light operation C 7 140 Speedometer operation 141 Exhaust gas leakage and noise gt Page 11 Each coupler disconnection Clogged oil cooler fins VL1500 Service Manual 3G 6 40 VLI500K5 05 MODEL SELF DIAGNOSTIC PROCEDURES NOTE Don t disconnect couplers from the ECM the battery cable from the battery ECM ground wire harness from the engine or main fuse before confirming the malfunction code self diag nostic trouble code stored in memory Such disconnection will erase the memorized information in ECM memory Malfunction code stored in ECM memory can be checked by the special tool Before checking malfunction code read SELF DIAGNOSIS FUNCTION USER MODE and DEALER MODE lt gt Page 33 and 36 carefully to have good understanding as to what func tions are available and how to use it Be sure to read PRECAUTIONS IN SERVICING F Page 19 before inspec
99. lve C s Page 14 Check that air flows through the air inlet port to the air outlet ports f air does not flow out replace the PAIR control solenoid valve with a new one o ry CGE i i i Air flow 1 gt Air flow Connect the 12 V battery to the PAIR control solenoid valve terminals and check the air flow e f air does not flow out the solenoid valve is in normal condi tion e Check the resistance between the terminals of the PAIR con trol solenoid valve Resistance 20 24 at 20 30 C 68 86 F 09900 25008 Multi circuit tester set Tester knob indication Resistance If the resistance is not within the standard range replace the PAIR control solenoid valve with a new one Installation is in the reverse order of removal Connect the lead wire coupler of the PAIR control solenoid valve and PAIR hoses securely PAIR system hose routing 175 VL1500K5 05 MODEL 173 174 VL1500K5 05 MODEL PAIR AIR SUPPLY SYSTEM DIAGRAM FRESH AIR No 2 cylinder EXHAUST GAS 1 From air cleaner PAIR control solenoid valve 2 To No 1 cylinder PAIR reed valve No 1 cylinder 3 To No 2 cylinder VL1500K5 05 MODEL 175 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 5555 20 40 mm Su 0 79 1 57 in 20
100. mal 0 4 1 4 V Leaning 3 7 44V When leaning 65 GP switch voltage 0 6 V and more From 1st to top Injector voltage Battery voltage STP sensor input voltage 45 5 5V STP sensor resistance Approx 4 69 kQ Closed Approx 0 5 kQ Opened Approx 3 9 kQ STP sensor output voltage Closed Approx 0 5 V Opened Approx 3 9 V STV actuator resistance Approx 6 5 Q Heated oxygen sensor output voltage 0 4 V and less at idle speed 0 6 V and more at 5 000 r min Heated oxygen sensor resis tance 6 5 8 9 Q at 23 C 73 4 F For E 02 19 24 PAIR solenoid valve resistance 20 24 Q at 20 30 C 68 86 F 164 11500 5 05 MODEL THROTTLE BODY SPECIFICATION ID No 10F0 For E 02 19 03 24 28 10F1 For E 33 Bore size 36 mm Fast idle r min 1 400 2 000 r min When cold engine Idle r min 1 000 100 r min Throttle cable play ELECTRICAL 2 0 4 0 mm 0 08 0 16 in SPECIFICATION Unit mm in Firing order R F Spark plug NGK DPR7EA 9 DENSO X22EPR U9 0 8 0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance CKP sensor peak voltage 178 242 Q 2 4 V and more Ignition coil resistance Primary 1 7 Q Terminal Terminal Secondary 18 28
101. meter unit 140 VL1500K5 05 MODEL INSPECTION LED LIGHT EMITTING DIODE Check that the LEDs illuminate Fl light and Oil pressure indica tor light immediately after turning the ignition switch on Also check the other LEDs for their lighting Neutral indicator light High beam indicator light and Turn signal indicator light in accordance with their switch positions If the LED fails in operation replace the speedometer unit with a new one after checking its wire harness coupler FUEL LEVEL GAUGE INSPECTION e Remove the fuel pump assembly L gt Page 96 Measure the resistance at each fuel level gauge float position If the resistance is incorrect replace the fuel level gauge with a new one Float position Resistance 34 8 mm 1 37 in 4 100 142 9 mm 5 63 in 90 100 Q FUEL LEVEL INDICATOR If the fuel level indicator B does not function properly check the fuel level gauge and its lead wire coupler If the fuel level gauge and its lead wire coupler are functioning properly replace the speedometer with a new one OIL PRESSURE INDICATOR NOTE Before inspecting the oil pressure switch check if the engine oil level is correct 7 VL1500 Service Manual 2 6 Disconnect the oil pressure switch lead wire from the oil pres sure switch Turn the ignition switch ON Check if the oil pressure indicator will light when grounding the lead wire If any indications are abnormal repl
102. n 2 0 4 0 mm 0 08 0 16 in e Tighten the lock nut while holding the adjuster Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable until resistance is felt Tighten the lock nut D while holding the adjuster Throttle cable play 2 0 4 0 mm 0 08 0 16 in After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically NOTE Major adjustment can be made by the throttle body side adjuster 10 11500 5 05 MODEL MAJOR ADJUSTMENT e Remove the air cleaner box 103 Loosen the locknut of the throttle returning cable e Turn the returning cable adjuster to obtain proper cable play Loosen the lock nut 3 of the throttle pulling cable e Turn the pulling cable adjuster in or out until the throttle cable play at the throttle grip is between 2 0 4 0 mm 0 08 0 16 in e Tighten the lock nut 3 securely while holding the adjuster 4 Throttle cable play 2 0 4 0 mm 0 08 0 16 in While holding the throttle grip at the fully closed position slowly turn the returning cable adjuster to obtain a slack of 1 0 mm 0 04 in Tighten the lock nut D securely After the adjustment is completed check that handle bar movement does not rai
103. n switch is ON the LCD displays CHEC But it is not a malfunction This condition implies that combination meter receives no signal from the ECM In that case they are restored to normal indication by turning the engine stop switch to RUN position LED Light Emitting Diode LED is used for the illumination light and each indicator light LED is maintenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb Z f NI m Select switch Odo Trip clock LED High beam indicator light Reset switch LED Fl indicator light Speedometer LCD Odo Trip A Trip B Clock Fl LED Oil pressure indicator light LCD Fuel level LED Turn signal indicator light LED Neutral indicator light REMOVAL AND DISASSEMBLY e Remove the seats gt Page 121 Remove the speedometer and fuel inlet cover CC VL1500 Service Manual 6 3 Remove the speedometer 1 CAUTION When disconnecting and reconnecting the speedome ter coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Disassemble the speedometer as follows VL1500K5 05 MODEL 139 D Select switch cover 3 Speedometer cover 2 Reset switch cover 4 Speedometer unit CAUTION Speedometer case Do not attempt to disassemble the Speedo
104. ndicated 2 When the secondary throttle valve actuator and secondary throttle position sensor signals are not sent to ECM In this case C28 and C29 are indicated alternately 36 11500 5 05 MODEL TPS ADJUSTMENT 1 Warm up the engine and adjust the engine idle speed to 1 000 100 r min Page 8 2 Connect the special tool Mode select switch and select the dealer mode 3 Remove the right frame upper cover C VL1500 Service Manual 6 3 4 Loosen the screws and turn the throttle position sensor D and bring the line to the middle 5 Then tighten the screws to fix the throttle position sensor 09930 11950 Torx wrench 09930 82720 Mode select switch The LCD displays the line for 0 4 sec at a time and when such a display repeats two times it indicates the current position where the sensor is fixed Incorrect Correct position VL1500K5 05 MODEL 37 FAIL SAFE FUNCTION FI system is provided with fail safe function to allow the engine to start and the motorcycle to run in a mini mum performance necessary even under malfunction condition ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY IAP sensor TP sensor Intake air pressure is fixed to 760 mmHg The throttle opening is fixed to full open position Ignition timing is also fixed VES VES YES YES EOT sensor IAT sensor Engine oil temperature value is fixed to 8
105. ndicating P1651 L 1 Remove the seats L7 Page 121 2 Turn the ignition switch OFF 3 Check the TO sensor coupler for loose or poor contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between Br W wire and ground 6 Also check the continuity between Br W wire and B Br wire If the sound is not heard from the tester the circuit condi tion is OK 7 Remove the left frame upper cover C gt VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between Red wire W and terminal 6 9 Also then check the continuity between Br W wire B and ter minal QJ TOS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK Go to Step 2 Red or Br W wire open or Br W wire shorted to ground 10 After repairing the trouble clear the DTC using SDS tool CC Page 42 ECM coupler Harness side Step 2 1 Connect the TO sensor coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switch ON 4 Measure the voltage at the wire side coupler between Black and B Br wires TO sensor voltage Normal 0 4 1 4 V Br W Also measure the voltage when l
106. nsor output voltage variation 0 064 0 096 V f the voltage variation is out of specification turn in or out the fast idle adjust screw to adjust the voltage to specification CAUTION The fast idle screw is factory adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary Cool down the engine to ambient air temperature and start the engine to check the fast idle rpm comes within the specified rpm Standard Fast idle rpm 1 400 2 000 r min Cold engine Idle rpm 1000 100 r min Warmed engine f it is not at the specified rpm the cause may possibly be short circuit in oil temperature sensor or wiring harness or STVA VL1500K5 05 MODEL 113 114 VL1500K5 05 MODEL THROTTLE VALVE SYNCHRONIZATION Check and adjust the throttle valve synchronization among two cylinders USE OF DIGITAL VACUUM TESTER Step 1 e Remove the seats Page 121 Remove the speedometer and fuel inlet cover frame head covers and upper frame covers C VL1500 Service Manual 6 3 Start up the engine and run it in idling condition for warming up Stop the warmed up engine Disconnect the IAP sensor couplers e Disconnect the IAP sensor vacuum hoses 2 from each throt tle body Connect the vacuum tester hoses to each vacuum nipple on the throttle body Step 2 Connect a tachometer and start up the engine
107. ntake air temperature circuit malfunction em Pre detect Detect poi Post dete Engine speed 1082 132 1175 Throttle position Manifold absolute pressure 98 1 93 5 98 1 Engine coolant temperature 378 378 378 Gear position Secondary throttle actuator position sensor e Click Show data when trouble D to display the data By clicking the drop down button 0 either Failure 1 or Failure 2 can be selected Diagnostic troubleshooting menu Data monitor Failure te ee Q PO115 H Engine coolant temperature circuit malfur DTG inspection Throttle position Show data when trouble Active control Manifold absolute pressure Engine coolant temperature Gear position Secondary throttle actuator position sensor 44 VL1500K5 05 MODEL MALFUNCTION CODE AND DEFECTIVE CONDITION C13 C17 P1750 P0105 DETECTED ITEM NO FAULT CKP sensor IAP sensor TP sensor EOT sensor Decomp relay Starter relay DETECTED FAILURE CONDITION The signal does not reach ECM for 3 sec or more after receiving the starter signal The sensor should produce following voltage 0 1 V x sensor voltage 4 8 V In other than the above range C13 P1750 or C17 P0105 is indicated The sensor should produce following voltage 0 1 V x sensor voltage
108. o if measured values are as listed below a resistance abnormality exists which causes the voltage drop in the circuit between terminals amp and B Voltage Between and body ground Approx 5 V and body ground Approx 5 V j 2 V voltage drop amp and body ground 3 V VL1500K5 05 MODEL 23 24 VL1500K5 05 MODEL SHORT CIRCUIT CHECK WIRE HARNESS TO GROUND Disconnect the negative cable from the battery Disconnect the connectors couplers at both ends of the circuit to be checked NOTE If the circuit to be checked branches to other parts as shown disconnect all connectors couplers of those parts Otherwise diagnosis will be misled e Measure resistance between terminal at one end of circuit terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals and Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal amp and body ground If continuity is indicated the circuit is shorted to the ground between terminals and B Other parts USING THE MULTI CIRCUIT TESTER Use the Suzuki multi circuit tester 09900 25008 Use well charged batteries in the tester Be sure to set the tester to the correct testing range USING THE TESTER Incorrectly connecting the and probes ma
109. or contacts If OK then check the EOT sensor lead wire continuity 3 Disconnect the EOT sensor coupler 4 Check the continuity between B BI wire D and ground If the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 5 Connect the EOT sensor coupler and turn the ignition switch ON 6 Measure the voltage between B BI wire 1 and ground EOT sensor output voltage 0 1 4 6 V B BI Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Are the continuity and voltage OK Go to Step 2 B BI wire or sub harness B BI wire shorted to ground f wire and sub harness are OK go to Step 2 7 After repairing the trouble clear the DTC using SDS tool 42 VL1500K5 05 MODEL 61 Step 2 1 Turn the ignition switch OFF 2 Disconnect the EOT sensor coupler 3 Measure the EOT sensor resistance EOT sensor resistance Approx 61 3 at 20 C 68 F White White 09900 25008 Multi circuit tester set Tester knob indication Resistance Q Refer to next page for details Is the resistance OK or B Br wire open or shorted to ground or poor or 9 connection ECM coupler Harness side Open or short circuit in the sub harness or sab harness connection If wire
110. ottle open STP sensor malfunction ing and opening calculated by ECM is ECM malfunction larger than specified value 0 1 V amp Sensor voltage 4 8 V P1654 H Sensor voltage is higher than specified STP sensor circuit shorted to VCC or ground cir value cuit open L Sensor voltage is lower than specified STP sensor circuit open or shorted to ground or value VCC circuit open ECM R VCC YW STP B Br E2 STP sensor INSPECTION Step 1 When indicating C29 1 Remove the air cleaner box C gt 103 2 Turn the ignition switch OFF 3 Check the STP sensor coupler for loose or poor contacts If OK then measure the STP sensor input voltage 4 Disconnect the STP sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage at the Red wire and ground 7 Also measure the voltage at the Red wire and B Br wire STP sensor input voltage 4 5 5 5 V Red Ground amp Red B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal or 44 Open or short circuit in the Red wire or B Br wire 78 VL1500K5 05 MODEL Step 1 When indicating P1654 H 1 Remove the air cleaner box Page 103 2 Turn the ignition switch OFF 3 Check the STP sensor coupler for loose or poor contacts If OK then ch
111. oupler side ground or poor D or connection D If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the HO2 sensor with a new one 6 After repairing the trouble clear the DTC using SDS tool Page 42 Step 1 When indicating C44 P0135 1 Remove the seats lt 7 Page 121 2 Turn the ignition switch OFF 3 Check the HO2 sensor for loose or poor contacts If OK then measure the HO2 sensor resistance 4 Disconnect the HO2 sensor coupler and measure the resis tance between terminals HO2 heater resistance 6 5 8 9 Q at 23 C 73 4 F White White NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature 09900 25008 Multi circuit tester set Tester knob indication Resistance Q Is the voltage OK YES Go to Step 2 NO Replace the HO2 sensor with a new one 5 After repairing the trouble clear the DTC using SDS tool C Page 42 90 11500 5 05 MODEL Step 2 When indicating C44 P0135 1 Connect the HO2 sensor coupler 2 Insert the needle pointed probes to the HO2 sensor coupler 3 Turn the ignition switch ON and measure the heater voltage between W B wire and ground 4 If the tester voltage indicates the ba
112. peration If the interlock system does not operate properly check each component for damage or abnormalities If any abnormality is found replace the component with a new one GEAR POSITION SWITCH e Remove the secondary gear case cover VL1500 Service Manual 3 7 Disconnect the gear position switch coupler D and check the continuity between Blue and Black with the transmission in NEUTRAL 09900 25008 Multi circuit tester set Tester knob indication Continuity test ON Neutral OFF Other than neutral CAUTION When disconnecting and connecting the gear position switch coupler make sure to turn OFF the ignition switch or electronic parts may get damaged Connect the gear position switch coupler to the wiring har ness Turn the ignition switch to ON position and side stand to upright position Insert the needle pointed probes to the gear position switch coupler Measure the voltage between Red Black and Black Green lead wires using the multi circuit tester when shifting the gear shift lever from low to top GP switch voltage 0 6 V and more R B B G Low to top gear positions except neutral position 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage CAUTION Use the special tool to prevent the rubber of the water proof coupler from damage
113. r close smoothly TP sensor setting procedure gt Page 36 Apply thin coat of the engine oil to the new fuel injector cush ion seal 3 and install it to the fuel injector CAUTION Replace the cushion seal and O ring with the new ones e Install the O ring to the fuel injector Apply thin coat of the engine oil to the new O ring Install the fuel injector amp by pushing it straight to the delivery pipe NOTE Align the boss of the injector with the groove of the delivery pipe CAUTION Never turn the injector while pushing it e Install the fuel delivery pipes along with the fuel injectors CAUTION Never turn the fuel injectors while installing them Tighten the fuel delivery pipe mounting screws to the speci fied torque V Fuel delivery pipe mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft Apply thin coat of the engine oil to the new O rings CAUTION Replace the O rings with the new ones Install the fuel delivery pipe joint hose to the delivery pipes Tighten the fuel delivery pipe hose mounting screws to the specified torque V Fuel delivery pipe joint hose mounting screw 3 5 N m 0 35 kgf m 2 5 Ib ft VL1500K5 05 MODEL 109 110 VL1500K5 05 MODEL THROTTLE BODY INSTALLATION Installation is in the reverse order of removal Pay attention to the following points
114. r repairing the trouble clear the DTC using SDS tool 42 VL1500K5 05 MODEL 49 C13 P1750 or C17 P0105 IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage low or high Clogged vacuum passage between throttle body 0 1 V lt Sensor voltage lt 4 8 V and IAP sensor NOTE Air being drawn from vacuum passage between Note that atmospheric pressure varies depending on throttle body and IAP sensor weather conditions as well as altitude IAP sensor circuit open or shorted to ground Take that into consideration when inspecting volt AP sensor malfunction age ECM malfunction IAP sensor 2 Front cylinder ECM R G B B Br R G W B Br IAP sensor 1 Rear cylinder INSPECTION Step 1 When indicating C13 P1750 for IAP sensor 2 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 For the other inspection procedures are the same as C17 P0105 When indicating C17 P0105 for IAP sensor 1 1 Remove the left frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the IAP sensor coupler Front cylinder side or Rear cylinder side 2 for loose or poor contacts If OK then measure the IAP sensor input voltage 4 Disconnect the IAP sensor coupler 5 Turn the ignition switch ON 6 Measure the voltage at the Red wire 3 and ground 1 7 Also measure the
115. r tube upper cover and protrusion on the steering stem lower bracket 126 11500 5 05 MODEL When installing the front fork assembly align the upper sur face D of the inner tube with the surface of the steering upper bracket Tighten the front fork lower clamp bolts 5 to the specified torque V Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Tighten the front fork cap bolt to the specified torque V Front fork cap bolt 23 N m 2 3 kgf m 16 5 Ib ft e Tighten the front fork upper clamp bolt to the specified torque V Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft e Tighten the steering stem head nut 8 to the specified torque V Steering stem head nut 90 N m 9 0 kgf m 65 0 Ib ft VL1500K5 05 MODEL 127 LOCATION OF ELECTRICAL COMPONENTS CD Fuel pump and level gauge Page 95 TO sensor Page 70 2 TP sensor Page 53 Starter motor IAP sensor Front Page 49 Oil pressure switch Ignition coil 2 2 EOT sensor Page 58 5 Horn Except for E 03 24 28 and 33 IAT sensor lt Page 66 Automatic decompression relay Speed sensor 141 Fuse box Battery Side stand turn signal relay Automatic decompression solenoid Horn is located under the ECM 128 VL1500K5 05 MODEL D Fuel injector 1 amp 2 7 Page 84 9 GP switch Page 82 2 STP sensor C7 Page 77 sensor For 02 19 2
116. rankshaft Position Engine speed fuel Sensor CKP Sensor signal injection T time Throttle Position Throttle opening Sensor TP Sensor signal Various Various signals Sensors Compensation T Ultimate Injectors Injection signal fuel injection time VL1500K5 05 MODEL 27 COMPENSATION OF INJECTION TIME VOLUME The following different signals are output from the respective sensors for compensation of the fuel injection time volume SIGNAL DESCRIPTION ENGINE OIL TEMPERATURE SENSOR SIGNAL When engine oil temperature is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low injection time volume is increased HEATED OXYGEN SENSOR SIGNAL FOR E 02 19 24 Air fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gasses The compensation occurs in such a way that more fuel is supplied if detected air fuel ratio is lean and less fuel is supplied if it is rich BATTERY VOLTAGE SIGNAL ENGINE RPM SIGNAL ECM operates on the battery voltage and at the same time it monitors the voltage signal for compensation of the fuel injection time volume A longer injection time is needed to adjust injection volume in the case of low voltage At high speed the injection time volume is increased STARTING SIGNAL When starting engine additional fuel is injected during cranking engine
117. rator ENGINE RIGHT SIDE Clutch cover Clutch pressure drive and driven plates Clutch sleeve hub Clutch housing Oil pump drive gears Oil pump driven gears Oil pressure switch Oil pressure regulator EOT sensor Back torque limiter Rear clutch cover ENGINE CENTER PARTS Throttle body Oil filter Oil cooler Starter motor REMOVAL 3 24 4 5 3 25 4 5 17 6 59 3 27 30 1 3 17 30 1 3 27 3D 1 3D 5 3 26 SE 1 3 27 3D 1 REMOVAL 3 20 3C 1 3 20 3C 1 3 21 3C 1 3 22 3C 2 3 22 3C 2 3 23 3 24 3G 5 3 23 3G 3 17 3 22 3C 2 3 6 REMOVAL INSTALLATION 3 41 4 10 3 40 4 10 17 6 61 3 36 3D 6 3 60 3D 6 3 38 3D 5 3D 6 3 38 3E 5 3 38 3D 6 INSTALLATION 3 50 3C 5 3 48 3C 5 3 46 3C 5 3 46 3C 4 3 46 3C 4 3 45 3 43 3G 7 3 45 3G 4 17 3 46 3C 5 3C 6 INSTALLATION 14 VL1500K5 05 MODEL ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL The engine removal procedure is different from that of the VL1500K4 04 MODEL For details other than the removal pro cedure refer to the VL1500 Service Manual Remove the seats Page 121 e Remove the PAIR cover Disconnect the PAIR hoses Q from the pipes Remove the PAIR control solenoid valve nuts e Disconnect the PAIR control solenoid valve coupler and PAIR hose e Remove the PAIR control solenoid valve 6 VL1500K5 05 MODEL 15 e Remove the PAIR device bracket
118. re coupler connection Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open Sensor voltage is lower than specified value The sensor voltage should be the fol lowing for 2 sec and more after igni tion switch is turned ON 0 2 V lt sensor voltage x 4 6 V In other than the above value C23 P1651 is indicated IAT sensor circuit shorted to ground TO sensor lead wire coupler connection Sensor voltage is higher than specified value TO sensor circuit open or shorted to VCC or ground circuit open Sensor voltage is lower than specified value CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 8 times or more continu ously In this case the code C24 P0351 or C25 P0352 is indicated When no actuator control signal is supplied from the ECM communica tion signal does not reach ECM or operation voltage does not reach STVA motor C28 P1655 is indicated STVA can not operate The sensor should produce following voltage 0 1 V x sensor voltage 4 8 V In other than the above range C29 P1654 is indicated TO sensor circuit shorted to ground or VCC circuit open Ignition coil lead wire coupler connection power supply from the battery STVA motor STVA lead wire coupler STP sensor lead wire coupler connection Sensor voltage is higher than specified value STP sensor circuit shorte
119. se the engine idle speed and that the throttle grip returns smoothly and auto matically THROTTLE VALVE SYNCHRONIZATION Inspect initially at 1 000 km 600 miles 2 month E 33 only and every 12 000 km 7 500 miles 24 months Inspect the throttle valve synchronization periodically CC Page 114 PAIR AIR SUPPLY SYSTEM Inspect every 12 000 km 7 500 miles 24 months Inspect the PAIR air supply system periodically 172 VL1500K5 05 MODEL 11 EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km 600 miles 2 month and every 12 000 km 7 500 miles 24 months thereafter Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque S ls Gasket ITEM N m kgf m Ib ft Exhaust pipe connector D OO 25 2 5 18 0 3X6 23 23 16 5 D 55 5 5 40 0 12 VL1500K5 05 MODEL CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km 600 miles 2 month and every 6 000 km 4 000 miles 12 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque Refer to VL1500 Service Manual 2 18 for the locations of the following nuts and bolts ITEM N m kgf m lb ft Front axle Front axle pinch bolt Brake disc bolt Front and Rear Front fork cap bolt Front fork upper clamp bolt Front fork lower clamp bolt Steering stem head nut Front brak
120. sor coupler and turn the ignition switch ON 5 Measure the voltage between Dg wire terminal D and ground 6 Also measure the voltage between Dg wire terminal 1 and B Br wire terminal 2 IAT sensor input voltage 4 5 5 5 V Dg Ground Dg B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Go to Step 2 Loose or poor contacts on the ECM coupler terminal or 4 Open or short circuit in the Dg wire or B Br wire Step 1 When indicating P0110 H 1 Remove the right frame upper cover C VL1500 Service Manual 6 3 2 Turn the ignition switch OFF 3 Check the IAT sensor coupler for loose or poor contacts If OK then check the IAT sensor lead wire continuity 4 Remove the left frame upper cover CC VL1500 Service Manual 6 3 5 Disconnect the IAT sensor coupler and ECM coupler 6 Check the continuity between Dg wire W and terminal 2 7 Also check the continuity between B Br wire B and terminal 4 IATS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK YES Go to Step 2 NO Dg wire or B Br wire open 8 After repairing the trouble clear the DTC using SDS tool C Page 42 VL1500K5 05 MODEL 67 ECM coupler Harness side 68 11500 5 05
121. stance 4 Disconnect the injector coupler and measure the resistance between terminals Injector resistance Approx 11 7 Q at 20 C 68 F Terminal Terminal VL1500K5 05 MODEL 85 5 then check the continuity between each terminal ground STP sensor continuity Q Infinity 09900 25008 Multi circuit tester set Tester knob indication Resistance Q Are the resistance and continuity OK Go to Step 2 Replace the injector with a new one CC Page 111 6 After repairing the trouble clear the DTC using SDS tool C Page 42 Step 2 1 Turn the ignition switch ON 2 Measure the injector voltage between Y R wire and ground Injector voltage Battery voltage Y R Ground NOTE Injector voltage can be detected only 3 seconds after ignition switch is turned ON 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 2 Gr B wire open or shorted to ground or poor connection Front cylinder side Gr W wire open or shorted to ground or poor connection Rear cylinder side If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Open circuit in the Y R wire 3 After repairing the troub
122. t DTC Follow the displayed instructions Diagnostic troubleshooting menu Data monitor D Show data when trouble Active control Quit Current DTG NIL Past DTC 2 Manifold absolute Engine coolant te SUZUKI DIAGNOSIS SYSTEM G DTC has been cleared successfully e Check that both Current DTC and Past DTC deleted NIL File View Tool Help Current NIL Past DTG NIL VL1500K5 05 MODEL 43 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC ECM stores the engine and driving conditions in the form of data as shown in the figure at the moment of the detection of a malfunction in its memory This data is called Show data when trouble Therefore it is possible to know engine and driving conditions e g whether the engine was warm or not where the motorcycle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that have been detected Its use is helpful when rechecking or diagnosing a trouble Failure 1 0110 I
123. tact Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any D Check for loose connection Check contact tension by inserting and removing rai 4 Check each terminal for bend and proper alignment ALA 1 0 Looseness of crimping Open Thin wire few strands left Continuity check e Measure resistance across coupler between and in the figure If no continuity is indicated infinity or over limit the circuit is open between terminals and Disconnect the coupler B and measure resistance between couplers and B If no continuity is indicated the circuit is open between cou plers and B If continuity is indicated there is an open cir cuit between couplers and or an abnormality in coupler or coupler VOLTAGE CHECK If voltage is supplied to the circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals and B Voltage Between and body ground Approx 5 V and body ground Approx 5 V and body ground OV Als
124. tance between terminal W and terminal TO sensor resistance 19 1 19 7 kQ Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Q Is the resistance OK YES Go to Step 2 NO Replace the TO sensor with a new one VL1500K5 05 MODEL 71 step 1 When indicating P1651 H 1 Remove the seats C7 Page 121 2 Turn the ignition switch OFF 3 Check the TO sensor coupler for loose or poor contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between Red wire Br W wire If the sound is not heard from the tester the circuit condition is OK 6 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler p Oa 21 7 Check the continuity between Br W wire B and terminal QU cun e 8 Also check the continuity between B Br wire and terminal 4 Es jf TOS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK YES Go to Step 2 NO Br W wire shorted to VCC or B Br wire open 9 After repairing the trouble clear the DTC using SDS tool C Page 42 72 11500 5 05 MODEL Step 1 When i
125. terminal B 6 Turn the throttle grip and measure the resistance TP sensor resistance Throttle valve is closed Approx 1 12 kQ Throttle valve is opened Approx 4 41 7 If OK then measure the TP sensor resistance at the test har ness terminals between terminal and terminal D TP sensor resistance Approx 4 66 kQ Terminal Terminal D 09900 25008 Multi circuit tester set 09900 28630 TPS test wire harness Tester knob indication Resistance Q Are the continuity and resistance OK Go to Step 3 Reset the TP sensor position correctly Replace the TP sensor with a new one 8 After repairing the trouble clear the DTC using SDS tool 42 TPS ECM TPS ECM Step 3 1 Connect the TP sensor coupler to the test harness 2 Turn the ignition switch ON 3 Measure the TP sensor output voltage at the coupler between BI B and C B Br by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 1 12 V Throttle valve is opened Approx 4 41 V 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK R B Br or BI B wire open or shorted to ground or poor or connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a
126. the highest peak voltage CKP sensor peak voltage 2 4 V and more Green Blue 09900 25008 Multi circuit tester set Tester knob indication Voltage If the peak voltage on the CKP sensor lead wire coupler is OK but on the ECM coupler is out of specification the wire harness must be replaced If both peak voltages are out of specification the CKP sensor must be replaced and re checked CKP SENSOR RESISTANCE e Remove the seats C 7 Page 121 Remove the speedometer and fuel inlet cover frame head covers and frame upper covers CC VL1500 Service Manual 6 3 Disconnect the CKP sensor lead wire coupler T Measure the resistance between the lead wires and ground If the resistance is not specified value the CKP sensor must be replaced CKP sensor resistance 178 242 Green Blue co Q Blue Ground CKP sensor 09900 25008 Multi circuit tester set pup Tester knob indication Resistance Q E x CKP sensor 138 VLI500K5 05 MODEL SPEEDOMETER DESCRIPTION This speedometer mainly consists of the stepping motor LCD Liquid Crystal Display and LED Light Emit ting Diode This speedometer is light thin and of high response compared to those currently in use because of this composition The speedometer pointer is driven by the stepping motor The LCD indicates Odo Trip A Trip B Clock Fl and Fuel level respectively NOTE If the engine stop switch is turned OFF while the ignitio
127. the ignition switch OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then measure the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between BI B wire amp and ground 6 Also check the continuity between BI B wire W and B Br wire If the sound is not heard from the tester the circuit condi tion is OK 7 Remove the left frame upper cover VL1500 Service Manual 6 3 and disconnect the ECM coupler 8 Check the continuity between BI B wire and terminal 0 9 Also check the continuity between Red wire B and terminal 6 TPS lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test ECM coupler Harness side Is the continuity OK Go to Step 1 53 and Go to Step 2 Red wire or BI B wire open or BI B wire shorted to ground 10 After repairing the trouble clear the DTC using SDS tool C Page 42 56 VL1500K5 05 MODEL Step 2 1 Turn the ignition switch OFF 2 Disconnect the TP sensor coupler 3 Install the test harness to the TP sensor 4 Check the continuity between terminal and ground TP sensor continuity co Q Infinity Terminal amp Ground 5 If OK then measure the TP sensor resistance at the test har ness terminals between terminal W and
128. tinuity with the multi circuit tester If any abnormality is found replace the respec tive switch assemblies with new ones 09900 25008 Multi circuit tester set IGNITION SWITCH HAZARD Ground ON engine is stopped OFF engine is running NOTE Before inspecting the oil pressure switch check the engine oil level gt VL1500 Service Manual 2 6 WIRE COLOR Black with Blue tracer B Black B W Black with White tracer B Y Black with Yellow tracer Br Brown Gr Gray B R Black with Red tracer Lbl Light blue O B Orange with Black tracer Lg Light green O R Orange with Red tracer O Orange O W Orange with White tracer R Red O Y Orange with Yellow tracer Y Yellow WIB White with Black tracer W White Y G Yellow with Green tracer Y W Yellow with White tracer VL1500K5 05 MODEL 143 BATTERY SPECIFICATIONS Type designation FTZ16 BS 1 Capacity 12 V 64 8 kC 18 Ah 10 HR Anode plates Stopper b Separator fiberglass plate D Filter Cathode plates 9 Terminal d Upper cover breather Safety valve 144 VL1500K5 05 MODEL WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING V 6 Nm 0 6 kgf m 4 5 Ib ft Z EG AN E EA S pan gt V 6Nm 0 6 kgf m 4 5 lb ft Oil pressur
129. tion and observe what is written there Remove the left frame head cover VL1500 Service Manual 6 3 e Connect the special tool to the dealer mode coupler at the wiring harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch ON and check the malfunction code to determine the malfunction part 09930 82720 Mode select switch SELF DIAGNOSIS RESET PROCEDURE After repairing the trouble turn OFF the ignition switch and turn ON again f the malfunction code indicates COO the malfunction is cleared Disconnect the special tool from the dealer mode coupler NOTE Even though the malfunction code C00 is indicated the previ ous malfunction history code still remains stored in the ECM Therefore erase the history code memorized in the ECM using SDS The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS VL1500K5 05 MODEL 41 USE OF SDS DIAGNOSTIC PROCEDURES Don t disconnect couplers from ECM the battery cable from the battery ECM ground wire harness from the engine or main fuse before confirming the malfunction code self diagnostic trouble code stored in memory Such disconnection will erase the memorized information in ECM memory Malfunction code stored
130. trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Replace the IAT sensor with a new one vi IAT sensor specification Intake Air Temp Resistance 20 C 68 F Approx 2 45 40 C 104 F Approx 1 148 kQ 60 C 140 F Approx 0 587 kQ 80 C 176 F Approx 0 322 kQ NOTE IAT sensor resistance measurement method is the same way as that of the EOT sensor Refer to page 62 for details 70 11500 5 05 MODEL C23 P1651 H L TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow e TO sensor circuit open or short ing for 2 sec and more after ignition TO sensor malfunction switch is turned ON ECM malfunction 0 2 x Sensor voltage 4 6 V Sensor voltage is higher than specified TO sensor circuit open or shorted to VCC or value ground circuit open Sensor voltage is lower than specified TO sensor circuit shorted to ground or VCC circuit value open TO SENSOR COM R Br W B Br INSPECTION Step 1 When indicating C23 1 Remove the seats lt 7 Page 121 2 Turn the ignition switch OFF 3 Check the TO sensor coupler for loose or poor contacts If OK then measure the TO sensor resistance 4 Disconnect the TO sensor coupler 5 Measure the resis
131. ttery voltage it is good condition Heater voltage Battery voltage W B Ground NOTE Battery voltage can be detected only before starting the engine 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 2 O W or W B wire open or shorted to ground or EUM coupler Harness side poor amp connection Recheck each terminal and wire harness for open circuit and poor connection If wire and connection are OK intermittent trou ble or faulty ECM Replace the ECM with a known good one and inspect it again Open or short circuit in the W B wire or O W wire Loose or poor contacts on the ECM coupler terminal 89 or HO2 sensor coupler 5 After repairing the trouble clear the DTC using SDS tool 42 VL1500K5 05 MODEL 91 C49 P1656 PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to PAIR valve circuit open or short ECM PAIR valve malfunction e ECM malfunction ECM Engine stop Side stand Ignition switch relay switch soL Br B ow o o7 ES To GP switch mm ES L_L_ PAIR control solenoid valve INSPECTION Step 1 1 Turn the ignition switch OFF 2 Check the PAIR control solenoid valve coupler for loose or poor contacts If
132. urate reinstallation CAUTION Never remove the STVA from the throttle body CAUTION Never remove the secondary throttle valve 6 and throttle valve D CAUTION Avoid removing the throttle valve adjuster unless absolutely necessary CAUTION The fast idle screw 9 is factory adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary THROTTLE BODY CLEANING Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions for proper use handling and storage Clean all passageways with a spray type carburetor cleaner and blow dry with compressed air CAUTION Do not use wire to clean passageways Wire can dam age passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the throttle body components Do not apply carburetor cleaning chemicals to the rubber and plastic materials INSPECTION Check following items for any damage or clogging O ring Throttle valve Secondary throttle valve Vacuum hose Delivery pipe joint hose njector cushion seal
133. w one 7 After repairing the trouble clear the DTC using SDS tool Page 42 82 VLI500K5 05 MODEL C31 P0705 GP SWITCH CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No Gear Position switch voltage Gear Position switch circuit open or short Switch voltage is not within the following range Gear Position switch malfunction Switch voltage 0 6 V ECM malfunction ECM Side stand relay To engine stop switch OON D Ignition GP switch switch L k K Neutral indicator light i 5574 1 1 XM Ic l Side stand switch TIT INSPECTION Step 1 1 Remove the secondary gear case cover VL1500 Service Manual 3 7 2 Turn the ignition switch OFF 3 Check the GP switch coupler for loose or poor contacts If OK then measure the GP switch voltage 4 5 6 7 8 9 Support the motorcycle with a jack Fold the side stand to up position Make sure the engine stop switch is in the RUN position Insert the needle pointed probe to the lead wire coupler Turn the ignition switch ON Measure the voltage at the wire side coupler between R B wire and B G wire when shifting the gearshift lever from 1st to Top GP switch voltage 0 6 V and more RIB B G 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage VL1500K5 05
134. y cause the inside of the tester to burnout f the voltage and current are not known make measure ments using the highest range When measuring the resistance with the multi circuit tester oo will be shown as 10 00 MQ and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use a needle pointed probe set to the back side of the lead wire coupler and connect the probes of tester to them Use a needle pointed probe set to prevent the rubber of the water proof coupler from damage 09900 25009 Needle pointed probe set VL1500K5 05 MODEL 25 26 VLI500K5 05 MODEL FI SYSTEM TECHNICAL FEATURES INJECTION TIME INJECTION VOLUME The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of the intake air pressure engine speed and throttle opening angle and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions pee ECM Intake Air Pressure Intake air pressure Sensor IAP Sensor signal Basic C

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