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