MOTORCYCLE
DATE:
May 16, 2006
PAGE:
1
OF
13
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
A
Handlebars assembly 1
Clamp 2
Allen bolt 4 8 × 30 mm
*Burring washer 4 OD:13.0 ID:8.5
Plastic cap 4
OD:11.0
For handlebar clamp
bolt
*Screw 1
5 × 35 mm For throttle
assembly
*Screw 1
5 × 30 mm
For left switch
*Screw 1
5 × 45 mm
For left switch
*Clip 1 For throttle cable
B Plastic cap 4
OD:10.0
For front brake and
clutch master cylinder
mounting bolts
C Strap 4 L:140
*D
Handlebar balancer weight 2 Right and Left
Screw 2 6 × 120 mm
Flange rubber cushion 2
Spacer 2 L:50.0
Washer 2 OD:16.0 ID:6.5 T:4.0
Rubber cushion 2
Spacer nut 2 6 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
G
Front fender 1
Allen bolt 4 8 × 40 mm
Plastic cap 4 OD:14.5
H
Front 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
K
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)
L
Reflex reflector 2 For limited market
*Washer 2 OD:12.0 ID:5.5
M Key holder 1
N Information label 1 For E-28 market
O
Warning label 13
For E-19
CC selection
Warning label 7
For E-19
CD selection
P Battery electrolyte container 1
Q
Owner’s manual set 1
Manual bag 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
T
L
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
OF
13
[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
A of the front side with specified
torque and then tighten the bolt
B of the rear
side.
FORWARD
HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.
MOTORCYCLE
DATE:
May 16, 2006
PAGE
: 3
OF
13
[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
C of the upper side with specified torque
and then tighten the bolt
D of the lower side.
HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.
MOTORCYCLE
DATE:
May 16, 2006
PAGE
: 4
OF
13
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
OF
13
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
C of the upper side with specified torque
and then tighten the bolt
D of 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
OF
13
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
300 mm
UP
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
OF
13
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
OF
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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
A is for pulling cable and cable B is 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
C.
2. Turn the adjuster
D in or out until the correct play.
3. Tighten the lock nut
C while holding the adjuster D.
#
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
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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
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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
E
N
E
R
G
Y
C
O
N
S
E
R
V
I
N
G
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40
A
P
I
S
E
R
V
I
C
E
S
J
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
G
Front 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
AA
BB
CC
GG
E
E
D
D
GG
HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.
MOTORCYCLE
DATE:
May 16, 2006
PAGE
: 11
OF
13
5. CABLE ROUTING [Page: 56]
HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.
MOTORCYCLE
DATE:
May 16, 2006
PAGE
: 12
OF
13
6. HARNESS ROUTING [Page: 57]
HAMAMATSU-NISHI P.O. BOX 1, 432-8611 HAMAMATSU, JAPAN.
MOTORCYCLE
DATE:
May 16, 2006
PAGE
: 13
OF
13
7. SAFETY CHECK OUT [Page: 58, 59, 60]
ENGINE AND TRANSMISSION
CHASSIS
COLD INFLATION TIRE PRESSURE
ELECTRICALS
ROAD TEST INSPECTION
After completion of the setting-up the motor-
cycle all the following items should be dou-
ble-checked to confirm that the operation and
function of the motorcycle are satisfactory.
Now, setting-up the motorcycle and pre-deliv-
ery inspection have been completed and the
motorcycle can be passed to the customer.
ITEM MEASURE SPECIFICATIONS
Engine oil Check/Refill 3 700 ml
Final drive gear oil
level
Check/Refill 200–220 ml
*Fuel tank Drain/Fill 14.0 L
Throttle cable Check/Adjust 2.0–4.0 mm
Idle r/min Check/Adjust
900–1 100 r/min
Exhaust system Leakage
Fuel system
connection
Leakage/Circlip
ITEM MEASURE SPECIFICATIONS
Disc brake (s) Clean/Fluid level
Front brake lever Check/Adjust *Position 3
Rear brake pedal Check/Adjust 95–105 mm
Clutch lever Check/Adjust Position 2
Oiling points
All necessary
points
Battery Filling electrolyte
Wiring and cable Routing/Operation
Wiring connectors Clean/Tight
Front fork Operation
Rear shock absorber Operation
Tighten all nuts
and
bolts
Torque those listed
in this manual
Cotter pins and
circlip
Fasteners, Check
Paint and chrome
Inspect/Wash and
polish
Information label
(For E-19, 28 market)
Select/Stick
Appropriate
language
Warning label
(For E-19 market)
Select/Stick
Appropriate
language
SOLO RIDING DUAL RIDING
FRONT
200 kPa
2.00 kgf/cm
2
29 psi
200 kPa
2.00 kgf/cm
2
29 psi
REAR
250 kPa
250 kgf/cm
2
36 psi
250 kPa
250 kgf/cm
2
36 psi
ITEM CHECK FOR
Light
Lighting/Adjust
Headlight high/low beam
Tail/Brake light
Lighting
Turn signal light
Position light
(Except for Canada and Australia)
Instrument Lights
Lighting
Speedometer light
High beam indicator light
Neutral indicator light
Turn signal indicator light
Oil pressure indicator light
*Fuel injection indicator light
*Combination display
Switch Operations
Operation
Ignition switch
Dimmer switch
Turn signal switch
Horn switch
Passing light switch
Hazard warning switch
Engine stop switch
Starter button
Brake switch
Clutch lever position switch
Side stand/ignition interlock
switch
ITEM CHECK FOR
Engine
Starting/Acceleration/
Smoothness/Noise
Transmission Operation/Noise
Clutch Operation/Noise
Brake Operation/Noise
Steering Stability
Suspension Operation
Control cables Operation/Proper return
Leakage Fuel/Oil/Exhaust
Speedometer Operation
Odometer/Trip meter Operation
/