California Air Tools 15020C Manuale Utente

99501-39590-01ESUPPLEMENTARY SERVICE MANUALUSE THIS MANUAL WITH:VZR1800 SERVICE MANUAL (99500-39293-01E)

VZR1800/ZL0 (’10-MODEL) 9CRANKSHAFT JOURNAL BEARINGSELECTION Crankshaft journal oil clearance:Standard: 0.010 – 0.028 mm (0.0004 – 0.0011 in)Serv

10 VZR1800/ZL0 (’10-MODEL)DRIVELINE/AXLESECONDARY GEAR SHIMSADJUSTMENTAdjust backlash and tooth contact by selecting shims. (Use two pieces of shi

VZR1800/ZL0 (’10-MODEL) 11FI SYSTEMFI SYSTEM PARTS LOCATIONA Tachometer/gear position B ISC valve (ISCV)C Intake air pressure sensor #2 (IAPS) D I

12 VZR1800/ZL0 (’10-MODEL)A Speedometer B Intake air temperature sensor (IATS)C PAIR control solenoid valve D Fuel injector #1E Fuel injector #2 F

VZR1800/ZL0 (’10-MODEL) 13EXHAUST SYSTEMCONSTRUCTION23 N·m (2.3 kgf-m, 16.5 lbf-ft)4.0 mm (0.16 in) and moreNo. 1No. 258 – 59 mm(2.28 – 2.32 in)42

14 VZR1800/ZL0 (’10-MODEL)FRONT FORKCONSTRUCTION"FWD1 O-ring 6 Oil seal stopper ring A Front fork cap bolt2 Spacer 7 Dust seal B Inner rod lo

VZR1800/ZL0 (’10-MODEL) 15REMOVAL AND DISASSEMBLY• Remove the headlight housing assembly. (Page 29)• Remove the front wheel. (VZR1800K6 9-9)• Re

16 VZR1800/ZL0 (’10-MODEL)• Remove the front fork cap bolt 4 from the inner rod by loos-ening the lock nut.• Remove the special tools.• Remove th

VZR1800/ZL0 (’10-MODEL) 17• Remove the inner rod/damper rod (cartridge) 8.• Extract the outer tube from the inner tube.NOTE:Be careful not to dam

18 VZR1800/ZL0 (’10-MODEL)INSPECTIONINNER AND OUTER TUBES• Inspect the inner tube outer surface and outer tube inner sur-face for scratches.• Insp

VZR1800/ZL0 (’10-MODEL) 1CONTENTSVZR1800/ZL0 (’10-MODEL)© COPYRIGHT SUZUKI MOTOR CORPORATION 2010This manual describes service specifications, ser

VZR1800/ZL0 (’10-MODEL) 19REASSEMBLYReassemble the front fork in the reverse order of disassembly.Pay attention to the following points:OIL SEAL A

20 VZR1800/ZL0 (’10-MODEL)• Tighten the damper rod bolt to the specified torque with thespecial tool.\ 09940-30221: Front fork cylinder holder&quo

VZR1800/ZL0 (’10-MODEL) 21FRONT FORK INNER ROD LOCK NUT• Tighten the lock nut 1 to the bottom of inner rod threads.FORK SPRING• Install the fork s

22 VZR1800/ZL0 (’10-MODEL)INSTALLATIONInstall the front fork in the reverse order of removal. Pay atten-tion to the following points:• Install the

VZR1800/ZL0 (’10-MODEL) 23STEERINGCONSTRUCTION"*11 Handlebar clamp 6 Steering stem upper bearing C Front fork upper clamp bolt2 Handlebar cla

24 VZR1800/ZL0 (’10-MODEL)REAR BRAKE CALIPER AND BRACKETINSTALLATION• Apply THREAD LOCK SUPER to the brake caliper bracketmounting bolt 1 and tigh

VZR1800/ZL0 (’10-MODEL) 25SPEEDOMETER AND TACHOMETERDESCRIPTIONThis speedometer and tachometer mainly consists of the stepping motor (except for t

26 VZR1800/ZL0 (’10-MODEL)TACHOMETER REMOVAL AND DISASSEMBLY• Remove the headlight housing assembly. (Page 30)• Remove the headlight upper cover.

VZR1800/ZL0 (’10-MODEL) 27ENGINE COOLANT TEMPERATURE METER ANDINDICATOR INSPECTIONECT sensor inspection (VZR1800K68-9)• Remove the right frame s

28 VZR1800/ZL0 (’10-MODEL)FUEL LEVEL METER INSPECTION• Lift and support the fuel tank. (VZR1800K66-3)• Disconnect the fuel pump lead wire couple

2 VZR1800/ZL0 (’10-MODEL)VZR1800/ZL0 (’10-MODEL)CONTENTSCOUNTRY AND AREA CODESThe following codes stand for the applicable country(-ies) and area(

VZR1800/ZL0 (’10-MODEL) 29HEADLIGHT HOUSING/TACHOME-TER AND HEADLIGHT COVER BRACEREMOVAL• Remove the bolts 1.☆ : Hooked part• Disconnect the headl

30 VZR1800/ZL0 (’10-MODEL)• Disconnect the front turn signal light couplers 0.• Remove the front turn signal lights B by removing themounting scre

VZR1800/ZL0 (’10-MODEL) 31BATTERY GROUND WIREINSTALLATIONThe battery ground wire fixing point was changed.ClampBattery ground wireLower crankcase

32 VZR1800/ZL0 (’10-MODEL)TIGHTENING TORQUEENGINEDRIVELINE/AXLECHASSISSERVICE DATANOTE:Any differences between the VZR1800/NK9 (’09-model) and VZR

VZR1800/ZL0 (’10-MODEL) 33CYLINDER + PISTON + PISTON RING Unit: mm (in)ITEM STANDARD LIMITCompression pressure(Automatic de-comp. actuated)* 900 –

34 VZR1800/ZL0 (’10-MODEL)CONROD + CRANKSHAFT Unit: mm (in)CLUTCH Unit: mm (in)ITEM STANDARD LIMITConrod small end I.D. 23.010 – 23.018(0.9059 – 0

VZR1800/ZL0 (’10-MODEL) 35SUSPENSION Unit: mm (in)WIRING DIAGRAMITEM STANDARD LIMITFront fork stroke 130(5.1)—Front fork spring free length* 390

36 VZR1800/ZL0 (’10-MODEL)WIRING HARNESS ROUTINGClampClampWiring harnessClampISC valveWiring harnessFace the lead wireto the lower.Set the speedom

VZR1800/ZL0 (’10-MODEL) 37ClampIgnition coil high tension cordWiring harnessPass the wiring harnessover the breather hose.Pass the lead wireoutsid

38 VZR1800/ZL0 (’10-MODEL)CABLE ROUTINGPass the throttle cables behind the right handlebar switch lead wire, brake switch lead wire and brake hose

VZR1800/ZL0 (’10-MODEL) 3INFORMATION LABELSA: AttachedVZR1800 VZR1800UF1 Noise label A (For E-03, 24, 33)2 Information label A (For E-03, 28, 33,

VZR1800/ZL0 (’10-MODEL) 39FRONT BRAKE HOSE ROUTING1414* 1* 3* 2* 5* 3* 4* 1* 4* 3* 11 Front brake hose* 2Tighten the bolt after positioning the br

40 VZR1800/ZL0 (’10-MODEL)REAR BRAKE HOSE ROUTING1 Stopper * 2 Clamp ends should face upward.2 Reservoir tank * 3Insert the reservoir hose fully t

VZR1800/ZL0 (’10-MODEL) 41COOLING SYSTEM HOSE ROUTINGRadiator capRadiatorMarkInside.White markRed markThermostatFace the tip of clip to the inside

42 VZR1800/ZL0 (’10-MODEL)FUEL TANK INSTALLATION1 Heat shield 6 Fuel tank cushion2 Fuel pump 7 Rear fender cover cushion3 Clamp 8 Apply instant ad

VZR1800/ZL0 (’10-MODEL) 43LEFT FRAME COVERS INSTALLATION1 Rear fender 5 Lower side cover2 Rear fender cover 6 Cushion3 Rear side cover 7 10 ± 2 mm

44 VZR1800/ZL0 (’10-MODEL)RIGHT FRAME COVERS INSTALLATION1 Rear fender 5 Lower cover2 Rear fender cover 6 Cushion3 Rear side cover 7 15 ± 2 mm (0.

VZR1800/ZL0 (’10-MODEL) 45HEADLIGHT COVER INSTALLATION1 Headlight lower cover 5 Headlight housing bracket cover * 1 To headlight2 Headlight housin

46 VZR1800/ZL0 (’10-MODEL)FRONT TURN SIGNAL LIGHT INSTALLATION1 Front turn signal cover 8 Headlight housing bracket cover2Front turn signal light

VZR1800/ZL0 (’10-MODEL) 47SECONDARY GEAR CASE COVER DAMPER INSTALLATIONREAR FENDER CUSHION INSTALLATION1 Secondary gear case cover 4 Secondary gea

Prepared byJanuary, 2010Part No. 99501-39590-01EPrinted in Japan48

4 VZR1800/ZL0 (’10-MODEL)SPECIFICATIONSNOTE:Any differences between the VZR1800/NK9 (’09-model) and VZR1800/ZL0 (’10-model) in specifications arei

Printed in JapanL0

VZR1800/ZL0 (’10-MODEL) 5LUBRICATION POINTSProper lubrication is important for smooth operation and long life of each working part of the motorcyc

6 VZR1800/ZL0 (’10-MODEL)ENGINE COMPONENTS INSPECTION AND SERVICINGCAMSHAFTEach exhaust camshaft I.D. code A has been changed which isstamped on t

VZR1800/ZL0 (’10-MODEL) 7CLUTCHCONSTRUCTION2.3 mm(0.09 in)3.4 mm (0.13 in)2.9 mm (0.11 in)3.0 mm (0.12 in)2.0 mm (0.08 in)ta Driven plate No. 1 b

8 VZR1800/ZL0 (’10-MODEL)INSPECTIONCLUTCH PLATE THICKNESSNOTE:Wipe off engine oil from the clutch plates with a clean rag.• Measure the thickness