Suzuki VX800L User manual

FOREWORD
The SUZUKI VX800 has been developed as a new
generation motorcycle. It is packed with highly
advanced design concepts including a V-2 engine,
a liquid cooling system, a new highly efficient
combustion system (TSCC), a fully transistorized
ignition system and a shaft drive mechanism.
Combined with precise control and easy handling
the VX800 provides excellent performance and
outstanding riding comfort.
This service manual has been produced primarily
for experienced mechanics whose job is to in-
spect, adjust, repair and service SUZUKI motor-
cycles. Apprentice mechanics and do- ti-yourself
mechanics, will also find this manual an extremely
useful repair guide. This manual contains the most
up-to-date information at the time of publication.
The rights are reserved to update or make correc-
tions to this manual at any time.
IMPORTANT
All street-legal SUZUKI motorcycles with engine
displacement of 5Occ or greater are subject to
Environmental Pro tee tion Agent y emission regula-
tions. These regulations set specific standards for
exhaust emission output levels as well as particular
servicing requirements. This manual includes
specific information required to properly inspect
and service VX800 in accordance with all EPA
regulations. It is strongly recommended that the
chapter on Emission Control, Periodic Servicing
and Carburetion be thoroughly reviewed before
any type of service work is performed.
Further information concerning the EPA emission
regulations and U.S. SUZUKI‘s emission control
program can be found in the U.S. SUZUKI EMIS-
SION CONTROL
VICE BULLETIN.
SUZUKI
PROGRAM MANUAL/SER-
MOTOR CORPORATION
Mo tort ycle Technical
Service Department
GENERAL INFORMATION
PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES
ENGINE
SHAFT DRIVE
COOLING SYSTEM
FUEL AND LUBRICATION
SYSTEM
1 ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMA T/ON
EMISSION CONTROL
INFORMA T/ON
VX800M (‘9 l-MODEL)
VX800N (‘92~MODEL)
VX8OOP (‘93-MODEL)
0 COPYRIGHTSUZUKI MOTOR CORPORATION 1990
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VIEW OF SUZUKI VX8OOL
LEFT SIDE
-
RIGHT SIDE
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CONTENTS
SERIAL NUMBER LOCA T/ON ................I............................ l_ 1
FUEL, OIL AND COOL A NT RECOMMENDA TION ..................I- 1
BREAK-IN PROCEDURES ................................................l_ 3
CYLINDER /DENT/FICA T/ON .............................................I_ 3
SPECIAL MATERIALS ......................................................l_ 4
PRECAUTIONS AND GENERAL INSTRUCTIONS ..................l- 7
SPECIFICA TIONS ............................................................l_ g
COUNTRY OR AREA .........................................................1-11
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l-l GENERAL INFORMATION
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification
Number) 0 is stamped on the steering head pipe. The engine
serial number @ is located on the rear side of the crankcase.
These numbers are required especially for registering the
machine and ordering spare parts.
FUEL, OIL AND COOLANT
RECOMMENDATION
n Suzuki recommends that customers use alcohol-free, un-
L.
3.
4.
leaded gasoline whenever possible.
Use of blended gasoline containing MTBE (Methyl Tertiary
Butyl Ether) is permitted.
Use of blended gasoline/alcohol fuel is permitted, provided
that the fuel contains not more than 10% ethanol. Gasoline/
FUEL (For U.S.A. model)
1. Use only unleaded gasoline of at least 87 pump octane by
the F method or 91 octane or higher rated by the
Research method.
alcohol fuel may contain up to 5% methanol if appropriate
cosolvents and corrosion inhibitors are present in it.
5. If the performance of the vehicle is unsatisfactory while
using blended gasoline/alcohol fuel, you should switch to
alcohol-free unleaded gasoline.
6. Failure to follow these guideline could possibly void appli-
cable warranty coverage. Check with your fuel supplier to
make sure that the fuel you intend to use meets the require-
ments listed above.
FUEL (For Canadian model)
Use only unleaded gasoline of at least
v method or 91 octane or higher
method.
87 pump octane by the
rated by the Research
FUEL (For the other models)
Gasoline used should be graded 85 - 95 octane by the Research
method or higher. An unleaded gasoline is recommended.
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GENERAL INFORMATION 1-2
ENGINE OIL (For U.S.A. model)
Suzuki recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SE or SF under the API
(American Petroleum Institute) classification system. The
viscosity rating is SAE 1OW/40. If an SAE 1OW/40 motor
oil is not available, select an alternate according to the fol-
lowing chart.
r r
ENGINE OIL (For the other models)
Make sure that the engine oil you use comes under API clas-
sification of SE or SF and that its viscosity rating is SAE
1OW/40. If an SAE 1OW/40 motor oil is not available, select
an alternate according to the following chart.
MULTIGRADE
TEMP. <
I
-30 -20-10 0 10 20 30 40
-22 -4 14 32 50 68 66 104
GEAR OIL (FINAL DRIVE GEAR BOX)
Use SAE 90 hypoid gear oil which is rated GL-5 under API classification system. If you operate the
motorcycle where ambient temperature is below 0°C (32” F), use SAE 80 hypoid gear oil.
BRAKE FLUID
Specification and classification: DOT4
WARNING:
* Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer,
do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling
the system, otherwise serious damage will result.
* Do not use any brake fluid taken from old or used or unsealed containers.
* Never reuse brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL
Use fork oil #lo.
COOLANT
Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distrilled water only.
WATER FOR MIXING
Use distrilled water only. Water other than distrilled water can corrode and clog the aluminum radiator.
ANTI-FREEZE/COOLANT
The coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the coolant should be
used at all times even though the atomospheric temperature in your area does not go down to freezing
point.
Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200NA anti-freeze/coolant. If this is not
available, use an equivalent which is compatible with an aluminum radiator.
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LIQUID AMOUNT OF WATER/COOLANT
Solution capacity (total): 1700 ml (I .8/l .5 US/Imp. qt)
For coolant mixture information, refer to cooling system section, page 5-2.
CAUTION:
Mixing of anti-freeze/coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If
the anti-freeze/coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure
to mix it above 50% even though the atmospheric temperature does not go down to the freezing point. -
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the
engine to maximum stresses. The future performance and reliability of the engine depends on the care and
restraint exercise during its early life. The general rules are as follows.
_
l Keep to these break-in engine speed limits:
Initial 800 km (500 miles)
: Below 4000 r/min
Up to 1600 km (1000 miles) : Below 6000 r/min
Over 1600 km (1000 miles) : Below 8500 r/min
l
Upon reaching an odometer reading of 1600 km (1000 miles) you can subject the motorcycle to full
throttle operation. However, do not exceed 8500 r/min at any time.
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No. 1, and No. 2 cylinder, as counted from rear to front
(as viewed by the rider on the seat).
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GENERAL INFORMATION 1-4
SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the VX800, and should be kept on hand
for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the
like. How to use them and where to use them are described in the text of this manual.
r
For U.S.A. model
MATERIAL
SUZUKI BRAKE FLUID
DOT3 & DOT4
99000-23110
SUZUKI GOLDEN CRUISE
1200NA
99000-99032-10x
SUZUKI SUPER GREASE ”
39000-25030
R
A”
For other models
SUZUKI BRAKE FLUID
DOT3 & DOT4
99000-23110
SUZUKI GOLDEN CRUISER
1200NA
99000-99032-10x
SUZUKI SUPER GREASE “A”
99000-25010
T
.
Brakes 2
.
Coolant 2
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Brake pedal pivot
Footrest pivot
Gearshift lever pivot
Side-stand pivot and spring
hook
Center stand pivot and spring
hook 2
O-ring of oil jet
Secondary bevel gear case
oil seal and O-ring
Final driven gear oil seal
Final driven bevel gear coupling
Starter motor armature bearing
and dust seal
Wheel bearing
Speedometer gear box dust seal
Steering stem bearing and
dust seal
3
4
4
4
7
8
8
8.
Brake pedal boss
Final driven gear spline and
O-ring
Swingarm spacer, bearing and
dust seal
8
8
8
PART
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1-5 GENERAL INFORMATION
MATERlAL PART
For U.S.A. model
PAGE
For other models
g g l Brakeca’iperax’e B-5
SUZUKI SILICONE GREASE
99000-25 100 SUZUKI SILICONE GREASE
99000-25100
l Valve stem
l Conrod big end bearing
l Countershaft and driveshaft
l Piston pin
l Crankshaft journal bearing
l Camshaft journal and cam face
l Rocker arm and shaft
l Starter motor housing end
bushing
3-30
3-37
3-43
3-56
3-45
3-58
3-60
7-12
SUZUKI MOLY PASTE SUZUKI MOLY PASTE
99000-25140 99000-25140
l Oil pressure switch 3-17
& $&+y ;~~~~~t i
gear case
SUZUKI BOND NO. 1207B SUZUKI BOND NO. 1215
99104-31140 99000-311 IO
l Cylinder head cover 3-60
@$zy @
SUZUKI BOND NO. 1216
99104-31160 SUZUKI BOND NO. 1216
99000-31160
l Secondary driven bevel gear
housing bolt
l Gearshift and stopper
l Cam sprocket bolt
l Final driven gear bearing
retainer screw
l Final driven joint stopper bolt
3-49
3-50
3-58
4-14
8-30
THREAD LOCK SUPER “1303” THREAD LOCK SUPER “1303”
99000-32030 99000-32030
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GENERAL INFORMATION 1-6
MATERIAL
For U.S.A. model PART PAGE
For other models
l Generator stator mounting 3-41
screw
l Generator lead wire guide 3-41
screw
l Final gear case securing bolt 4-19
l Starter motor housing screw 7-12
l Front fork damper rod bolt 8-12
THREAD LOCK “1342”
99000-32050 THREAD LOCK “1342”
99000-32050
l Oil pipe retainer bolt
l Gearshift cam stopper bolt
l Gearshift cam driven gear bolt
l Gearshift cam guide nut and
paw1 lifter screw
l Oil pump securing bolt
l Brake pedal boss bolt
l Front footrest bolt
3-45
3-49
3-50
3-50
3-51
8-25
8-39
THREAD LOCK SUPER THREAD LOCK SUPER
“1333B” “1 322”
99000-32020 99000-32 110
l Crankcase bearing retainer
screw and bolt 3-18
THREAD LOCK SUPER “1303” THREAD LOCK SUPER “1324”
99000-32030 99000-32120
l Brake disc mounting bolt 8-3
8-30
THREAD LOCK SUPER “1360” THREAD LOCK SUPER “1360”
99000-32 130 99000-32 130
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l-7 GENERAL INFORMATION
THREAD LOCK SUPER “1303” THREAD LOCK SUPER “1305”
99000-32030 99000-32 100
PRECAUTIONS AND GENERAL INSTRUCTIONS
Observe the following items without fail when servicing, disassembling and reassembling motorcycles.
0 Do not run engine indoors with little or no ventilation.
0 Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones.
CAUTION:
*
*
*
0
q
0
cl
0
Never reuse a circlip. After a circlip has been removed from a
circlip must be installed.
shaft, it should be discarded and a new
When installing a new circlip, care must be taken not to expand the end gap larger than required to slip
the circlip over the shaft.
After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to out-side diagonally, to the specified tightening torque.
Use special tools where specified.
Use genuine parts and recommended oils.
When 2 or more persons work together, pay attention to the safety of each other.
After the reassembly, check parts for tightness and operation.
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