Suzuki VL1500K7 Reference manual

MOTORCYCLE

DATE:

May 16, 2006

PAGE:

SUBJECT:

NOTICE OF SET-UP MANUAL

APPLICABLE MODEL:

VL1500K7

EFFECTIVE ENGINE OR FRAME NO.:

REFERENCE:

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

This bulletin is to inform you of set-up procedures of VL1500K7.

Please inform your dealers of this notice.

VL1500K7 set-up manual will not be issued because the set-up procedures for this model remain

unchanged from VL1500K4 except the differences described below.

To set-up VL1500K7, please use the VL1500K4 set-up manual and this service bulletin.

DIFFERENCE BETWEEN VL1500K4 AND VL1500K7

VL1500K4 set-up manual: 99505-01074-011

1. LOCATION OF PARTS [Page: 2, 4, 6]

Item Part Name Q’ty Remarks

Handlebars assembly 1

Clamp 2

Allen bolt 4 8 × 30 mm

*Burring washer 4OD:13.0 ID:8.5

Plastic cap 4

OD:11.0

For handlebar clamp

bolt

*Screw 15 × 35 mm For throttle

assembly

*Screw 15 × 30 mm

For left switch

*Screw 15 × 45 mm

For left switch

*Clip 1For throttle cable

B Plastic cap 4

OD:10.0

For front brake and

clutch master cylinder

mounting bolts

C Strap 4 L:140

Handlebar balancer weight 2Right and Left

Screw 26 × 120 mm

Flange rubber cushion 2

Spacer 2L:50.0

Washer 2OD:16.0 ID:6.5 T:4.0

Rubber cushion 2

Spacer nut 26 mm

E Rear view mirror 2 Right and Left

F Plastic cap 4

OD:12.0

For front brake caliper

mounting bolts

Item Part Name Q’ty Remarks

Front fender 1

Allen bolt 4 8 × 40 mm

Plastic cap 4 OD:14.5

HFront brake hose guide 2 Right and Left

Flange bolt 2 6 × 12 mm

I Front wheel assembly 1

J Front wheel spacer 2 Right and Left

Plastic cap 1 OD:14.5

For axle clamp bolt

Plastic cap 1 OD:18.0

For front axle (Right)

Plastic cap 1 OD:28.5

For front axle (Left)

Steel cap 2

OD:45.0

For rear axle

(Right and Left)

LReflex reflector 2 For limited market

*Washer 2OD:12.0 ID:5.5

M Key holder 1

N Information label 1 For E-28 market

Warning label 13 For E-19

CC selection

Warning label 7 For E-19

CD selection

P Battery electrolyte container 1

QOwner’s manual set 1

Manual bag 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE: The parts shown as Item L, N and O in the above table are supplied for limited markets.

Please hand over the parts shown as Item M in the above table to your customer together with motor-

cycle.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 2

[Page: 7, 8 Paragraph: 1]

The photograph shown indicates the parts dismounted

from the motorcycle in addition to the items shown in

the preceding page.

A: Front brake master cylinder

B: Clutch master cylinder

C: Throttle assembly

D: Left switch

2. ASSEMBLY

HANDLEBARS [Page: 9, 10 Paragraph: 1, 2]

Install the handlebars assembly using the two clamps,

four Allen bolts and washers.

A: Clamp

B: 8 × 30 mm Allen bolt

C: Barring washer OD:13.0 mm ID:8.5 mm

D: Plastic cap OD:11.0 mm

E: Punch mark

F: Dot mark

Tighten the handlebar clamp bolts to the specified

torque.

"Handlebar clamp bolt: 16 N·m (1.6 kgf-m)



After installing the handlebars, fit the plastic cap on the

head of each bolt.

A: 8 × 30 mm Allen bolt

B: 8 × 30 mm Allen bolt

C: Plastic cap OD:11.0 mm

D: Punch mark

E: Dot mark

NOTE:

Install the burring washer in the direction as

shown in the illustration.

The punch mark on the clamps shows front

side.

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

NOTE:

To install the handlebars correctly, first tighten

the bolt



Aof the front side with specified

torque and then tighten the bolt



Bof the rear

side.

FORWARD

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 3

[Page: 9, 10 Paragraph: 3]

A: Front brake hose

B: Clutch hose

C: Throttle cable

D: Right switch wiring harness

E: Left switch wiring harness

THROTTLE [Page: 9, 10 Paragraph: 4]

Insert the boss of the throttle housing into the hole on

the handlebars.

Tighten the throttle assembly with two screws.

A: Boss

B: Hole

C: 5 × 45 mm screw

D: 5 × 35 mm screw

FRONT BRAKE MASTER CYLINDER

[Page: 11, 12 Paragraph: 2 through 4]

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

After installing the master cylinder, fit the plastic cap

on the head of each bolt.

A: Holder

B: Front brake master cylinder

C: 6 × 20 mm Allen bolt

D: 6 × 20 mm Allen bolt

E: Dot mark

F: Plastic cap OD:10.0 mm

The line drawings on page 56 and 57 show the

proper routing of the control cables, hose and

wirings.

Refer to them in addition to following the

instructions carefully.

Check to ensure that the throttle operates

freely and closes automatically.

NOTE:

To install the holder correctly, first tighten the

bolt



Cof the upper side with specified torque

and then tighten the bolt



Dof the lower side.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 4



A: Allen bolt

B: Holder

C: Front brake master cylinder

D: Handlebars

Connect the front brake light switch lead wires coupler

to the brake light switch.

A: Front brake light switch

B: Lead wire coupler

LEFT SWITCH [Page: 13, 14 Paragraph: 1]

Insert the boss of the left switch holder into the hole on

the handlebars.

Tighten the left switch assembly with the two screws.



A: Boss

B: Hole

C: 5 × 45 mm screw

D: 5 × 30 mm screw

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

Be careful not to pinch the wiring harness

between the housing and holder.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 5

CLUTCH MASTER CYLINDER

[Page: 13, 14 Paragraph: 3, 4]

Install the clutch master cylinder onto the handlebars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Clutch master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

After installing the master cylinder, fit the plastic cap

on the head of each bolt.

A: Holder

B: Clutch master cylinder

C: 6 × 20 mm Allen bolt

D: 6 × 20 mm Allen bolt

E: Dot mark

F: Plastic cap OD:10.0 mm



A: Allen bolt

B: Holder

C: Clutch master cylinder

D: Handlebars

RIGHT

CLAMP [Page: 15, 16 Paragraph: 2, 3]

Clamp the right handlebar switch wiring harness, front

brake hose union or front brake hose with straps as

shown in the photograph.

A: Strap L:140 mm

B: Right switch wiring harness

C: Front brake hose union

D: Front brake hose

NOTE:

To install the holder correctly, first tighten the

bolt



Cof the upper side with specified torque

and then tighten the bolt



Dof the lower side.

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for clutch fluid leakage.

NOTE:

Cut the remaining of the strap as shown in the

photograph.

OUTSIDE

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 6

LEFT

Clamp the left handlebar switch wiring harness, clutch

hose union or clutch hose with straps as shown in the

photograph.

A: Strap L:140 mm

B: Left switch wiring harness

C: Clutch hose union

D: Clutch hose

Fit the cable clip to the throttle cables as shown in the

photograph.

A: Clip

B: Throttle cable (pulling cable)

C: Throttle cable (returning cable)

HANDLEBAR BALANCER

[Page: 15, 16 Paragraph: 4]

Assemble the handlebar balancer parts as shown.

A: 6 × 120 mm screw

B: Balancer weight

C: Flange rubber cushion

D: Spacer L:50.0 mm

E: Washer OD:16.0 mm ID:6.5 mm T:4.0 mm

F: Rubber cushion

G: 6 mm spacer nut

REFLEX REFLECTOR (FOR LIMITED MARKET)

[Page: 25, 26 Paragraph: 4]

Install the reflex reflectors to the front fork leg.



A: Reflex reflector

B: Reflex reflector stay

C: Washer OD:12.0 mm ID:5.5 mm

NOTE:

Cut the remaining of the strap as shown in the

photograph.

OUTSIDE

300 mm

When installing the reflex reflectors to the front

fork leg, tighten the reflex reflector stay.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 7

WARNING AND INFORMATION LABEL

(FOR E-19 CC AND CD SELECTION,

FOR E-28 MARKET)

[Page: 29, 30 Paragraph: 2]

Stick the label selected for your country.

A: Warning label

B: Information label

C: Fuel tank lid

D: Back of fuel tank lid

LEFT

OWNER’S MANUAL

[Page: 31, 32 Paragraph: 1, 2]

Remove the left frame cover using the key.

Remove the tool box lid.

A: Left frame cover

B: Ignition key

C: Boss

D: Tool box lid

E: Click

F: Boss

Store the owner’s manual in place.

Reinstall the tool box lid and left frame cover.

A: Owner’s manual

NOTE:

When sticking the new label, remove the origi-

nal label.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 8

3. SERVICING

CLUTCH AIR BLEEDING

[Page: 43, 44 Paragraph: 2]

Disconnect the regulator/rectifier lead wire coupler.

A: Coupler

FRONT BRAKE LEVER

[Page: 45, 46 Paragraph: 1]

Make sure the front brake lever position is correct.

The standard setting for this motorcycle is as indicated

in the table below.

A: Adjuster

THROTTLE CABLE [Page: 45, 46 Paragraph: 3, 4]

This motorcycle has a twin throttle cable system.

Cable



Ais for pulling cable and cable



Bis for return-

ing.

Check the throttle cable play at the throttle grip.

Throttle cable play: 2.0–4.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Loosen the throttle cable adjuster lock nut



2. Turn the adjuster



Din or out until the correct play.

3. Tighten the lock nut



Cwhile holding the adjuster



Standard setting 3

2.0–4.0 mm

After the adjustment is completed, check that

handlebar movement does not raise the engine

idle speed and that the throttle grip returns

smoothly and automatically.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 9

ENGINE OIL [Page: 49, 50 Paragraph: 3]

Engine oil

Oil quality is a major contributor to your engine’s per-

formance and life.

Always select good quality engine oil.

Use SF/SG or SH/SJ in API (American Petroleum

Institute) classification, with MA in JASO.

SAE Engine Oil Viscosity

Suzuki recommends the use of SAE 10W-40 engine

oil.

If SAE 10W-40 engine oil is not available, select an

alternative according to the following chart.

JASO T903

The JASO T903 standard is an index to select engine

oils for 4-stroke motorcycle and ATV engines.

Motorcycle and ATV engines lubricate clutch and

transmission gears with engine oil.

JASO T903 specifies performance requirements for

motorcycle and ATV clutches and transmission.

There are two classes, MA and MB.

The oil container has following classification for con-

firming the standard.

A: Code number of oil sales company

B: Oil classification

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

API: American Petroleum Institute

JASO: Japanese Automobile Standards Organization

-30 -20 -10 0 10 20 30 40

-22 -4 14 32 50 68 86 104

10W - 30

20W - 50

10W - 40 10W - 50

15W - 40 15W - 50

˚C

˚F

ENGINE OIL VISCOSITY RATING SELECTION CHART

ENGINE OIL

TEMP.

HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.

MOTORCYCLE

DATE:

May 16, 2006

PAGE

: 10

Energy Conserving

Suzuki does not recommend the use of “ENERGY

CONSERVING” oils.

Some engine oils which is API SH or greater has

“ENERGY CONSERVING” indication in API classifica-

tion doughnut mark.

These oils can affect engine life and clutch perform-

ance.

IDLE SPEED ADJUSTMENT

[Page: 51, 52 Paragraph: 2]

After completing all of the servicing procedures and

the test ride, adjust the engine idle speed by turning

the throttle stop screw knob.

Engine idle speed: 900–1 100 r/min

A: Throttle stop screw knob

RecommendedNot recommended

SAE

10W-40

SAE

10W-40

NOTE:

The engine idle should be adjusted with engine

warmed up.

4. TIGHTENING TORQUE [Page: 53, 54, 55]

Item Part Name N·m kgf-m

FRONT FORK

A Handlebar clamp bolt 16 1.6

B Steering stem head nut 90 9.0

*C Handlebar holder nut 70 7.0

*D Front fork upper bracket bolt 23 2.3

E Front fork lower bracket bolt 23 2.3

F Front axle clamp bolt 23 2.3

BRAKE

GFront brake and clutch master cylinder

mounting bolt 10 1.0

H Front brake caliper mounting bolt 35 3.5

I Rear brake master cylinder mounting bolt 10 1.0

J Rear brake caliper mounting bolt 35 3.5

Item Part Name N·m kgf-m

K Rear brake push rod lock nut 18 1.8

L Brake caliper air bleeder (Front) 7.5 0.75

M Brake caliper air bleeder (Rear) 7.5 0.75

AXLE

N Front axle 65 6.5

O Rear axle nut 110 11.0

ABSORBER

P Rear shock absorber nut (Upper) 50 5.0

Q Rear shock absorber nut (Lower) 50 5.0

OTHERS

R Rear swingarm pivot nut 100 10.0

S Front footrest bolt 50 5.0

BBCC

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