Suzuki Intruder VZ800 User manual

VZ800
Printed in Japan
K5
VZ800
No.5230 99500-38050-01E VZ800K5 Service Manual 2004. 11. 29 Cover_14 for PS printing (16 mm)
TOP
BOTTOM
K5
99500-38050-01E
DIC75

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
SHAFT DRIVE 4
FI SYSTEM 5
FUEL SYSTEM AND THROTTLE
BODY 6
COOLING AND LUBRICATION
SYSTEM 7
CHASSIS 8
ELECTRICAL SYSTEM 9
SERVICING INFORMATION 10
EMISSION CONTROL
INFORMATION 11
WIRING DIAGRAM 12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
FOREWORD
This manual contains an introductory description on
the SUZUKI VZ800 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.

* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
SAMPLE

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1Front axle 6Brake disc
2Bearing (R) 7Spacer 
3Front wheel ITEM N·m kgf-m lb-ft
4Spacer AFront axle A65 6.5 47.0
5Bearing (L) BBrake disc mounting bolt B23 2.3 16.5
SAMPLE

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply oil. Use engine oil unless other-
wise specified.
Use engine coolant.
99000-99032-11X
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Use fork oil.
99000-99044-L01
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140 Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100 Measure in resistance range.
Apply SUZUKI BOND “1207B”.
99000-31140 Measure in current range.
Apply SUZUKI BOND “1216B”.
99000-31230 Measure in diode test range.
Apply THREAD LOCK SUPER “1303”.
99000-32030 Measure in continuity test range.
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA) Use special tool.
Apply THREAD LOCK “1342”.
99000-32050 Indication of service data.
1216
SAMPLE

ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
ATM Pressure: Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
EOT Sensor : Engine Oil Temperature
Sensor (EOTS), Oil Temp.
Sensor
EVAP : Evaporative Emission
EVAP
Canister : Evaporative Emission
Canister (Canister)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
G
GEN : Generator
GND : Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
SAMPLE

M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOx : Nitrogen Oxides
O
OHC : Over Head Camshaft
OPS : Oil Pressure Switch
P
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
SAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
STC System : Secondary Throttle Control
System (STCS)
STP Sensor : Secondary Throttle Position
Sensor (STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
SAMPLE

WIRE COLOR
B : Black Gr : Gray R : Red
Bl : Blue Lbl : Light blue W : White
Br : Brown Lg : Light green Y : Yellow
Dg : Dark green O : Orange
G : Green P : Pink
B/Bl : Black with Blue tracer B/Br : Black with Brown tracer
B/G : Black with Green tracer B/Lg : Black with Light green tracer
B/R : Black with Red tracer B/W : Black with White tracer
B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer
Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer
Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer
Br/B : Brown with Black tracer Br/W : Brown with White tracer
G/B : Green with Black tracer G/W : Green with White tracer
G/Y : Green with Yellow tracer Gr/B : Gray with Black tracer
Gr/R : Gray with Red tracer Gr/W : Gray with White tracer
Lg/G : Light green with Green tracer O/B : Orange with Black tracer
O/BI : Orange with Blue tracer O/G : Orange with Green tracer
O/R : Orange with Red tracer O/W : Orange with White tracer
O/Y : Orange with Yellow tracer P/W : Pink with White tracer
R/B : Red with Black tracer R/Bl : Red with Blue tracer
W/B : White with Black tracer W/Bl : White with Blue tracer
W/R : White with Red tracer Y/B : Yellow with Black tracer
Y/Bl : Yellow with Blue tracer Y/G : Yellow with Green tracer
Y/R : Yellow with Red tracer Y/W : Yellow with White tracer
SAMPLE

1
GENERAL INFORMATION 1-1
CONTENTS
GENERAL INFORMATION
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
SUZUKI VZ800K5 (’05-MODEL) ...................................................................1- 4
SERIAL NUMBER LOCATION ......................................................................1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION .......................1- 4
FUEL (FOR USA AND CANADA) ..........................................................1- 4
FUEL (FOR OTHER COUNTRIES) ........................................................1- 4
ENGINE OIL ...........................................................................................1- 5
BRAKE FLUID ........................................................................................1- 5
FRONT FORK OIL .................................................................................1- 5
ENGINE COOLANT ...............................................................................1- 5
WATER FOR MIXING ............................................................................1- 5
ANTI-FREEZE/ENGINE COOLANT .......................................................1- 5
LIQUID AMOUNT OF WATER/ENGINE COOLANT .............................1- 5
BREAK-lN PROCEDURES ...........................................................................1- 6
CYLINDER IDENTIFICATION .......................................................................1- 6
INFORMATION LABELS ...............................................................................1- 7
SPECIFICATIONS .........................................................................................1- 8
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA EFFECTIVE FRAME NO.
E-02
E-03
E-19 (VZ800)
E-19 (VZ800U)
E-24
E-28
E-33
U.K.
U.S.A. (Except for California)
E.U.
E.U.
Australia
Canada
California (U.S.A.)
JS1B4111200100001 –
JS1VS56A 52100001 –
JS1B4111100100001 –
JS1B4211100100001 –
JS1B4111300100001 –
JS1VS56A 52100001 –
JS1VS56A 52100001 –
SAMPLE

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
SAMPLE

GENERAL INFORMATION 1-3

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head and case bolts or nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
SAMPLE