suzuki VZ800
WORKSHOP, SERVICE, REPAIR MANUAL
SUZUKI VZ800 - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop Manual, to Suzuki VZ800. CONTENTS: FOREWORD HOW TO USE THIS MANUAL - To locate what you are looking for - Component parts and work to be done - Symbol - Abbreviations used in this manual - Sae-to-former suzuki term - Wire color 01 GENERAL INFORMATION - Warning/caution/note - General precautions - Suzuki vz800k5 (’05-model) - Serial number location - Fuel, oil and engine coolant recommendation - Fuel (for usa and canada) - Fuel (for other countries) - Engine oil - Brake fluid - Front fork oil - Engine coolant - Water for mixing - Anti-freeze/engine coolant - Liquid amount of water/engine coolant - Break-in procedures - Cylinder identification - Information labels - Specifications 02 PERIODIC MAINTENANCE - Periodic maintenance schedule - Periodic maintenance chart - Lubrication points - Maintenance and tune-up procedures - Air cleaner - Spark plug - Valve clearance - Fuel hose - Engine oil and oil filter - Engine idle speed - Throttle cable play - Throttle valve synchronization - Evaporative emisson control sys-tem (for e-33 only) - Pair (air supply) system - Clutch - Cooling system - Final gear oil - Brake - Tire - Steering - Front fork - Rear suspension - Exhaust pipe bolt - Chassis bolt and nut - Compression pressure check - Compression test procedure - Oil pressure check - Oil pressure test procedure - Sds check - Sample: - Data sampled from cold starting through warm-up - Data at 3000 r/min under no load - Data at the time of racing 03 ENGINE - Engine components removable with engine in place - Engine removal and installation - Engine removal - Engine installation - Engine disassembly - Engine components inspection and servicing - Cylinder head cover - Camshaft - Cam chain tensioner and guide - Cylinder head - Cylinder - Piston - Conrod/crankshaft - Clutch - Generator/signal generator/ starter clutch - Oil pump - Transmission - Gearshift fork - Oil jet - Crankcase - Engine reassembly 04 SHAFT DRIVE - Secondary bevel gears - Construction - Removal - Disassembly - Inspection - Secondary gear shims adjustment - Reassembly - Installation - Final bevel gears - Construction - Final gear case removal - Final gear case disassembly - Final gear shims adjustment - Final gear case reassembly - Final gear case installation 05 FI SYSTEM - Precautions in servicing - Connector/coupler - Fuse - Ecm/various sensors - Electrical circuit inspection procedure - Using the multi-circuit tester - Fi system technical features - Injection time (injection volume) - Compensation of injection time (volume) - Injection stop control - Fi system parts location - Fi system wiring diagram - Ecm terminal - Self-diagnosis function - User mode - Dealer mode - Tps adjustment - Fail-safe function - Fi system troubleshooting - Customer complaint analysis - Visual inspection - Self-diagnostic procedures - Self-diagnosis reset procedure - Use of sds diagnostic procedures - Use of sds diagnosis reset proce-dure - Show data when trouble (displaying data at the time of dtc) - Malfunction code and defective condition - “c12” (p0335) ckp sensor circuit malfunction - “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction - “c14” (p0120-h/l) tp sensor circuit malfunction - “c15” (p0115-h/l) ect sensor circuit malfunction - Ect sensor inspection - “c21” (p0110-h/l) iat sensor circuit malfunction - “c23” (p1651-h/l) to sensor circuit malfunction - “c24” (p0351) or “c25” (p0352) ignition system malfunction - “c28” (p1655) stv actuator circuit malfunction - “c29” (p1654-h/l) stp sensor circuit malfunction - “c31” (p0705) gp switch circuit malfunction - “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction - “c41” (p0230) fp relay circuit malfunction - “c42” (p01650) ig switch circuit malfunction - “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24) - “c49” (p1656) pair control solenoid valve circuit malfunction - Sensors - Iap sensor inspection - Iap sensor removal/installation - Tp sensor inspection - Tp sensor removal/installation - Stp sensor inspection - Stp sensor removal/installation - Ckp sensor inspection - Ckp sensor removal/installation - Iat sensor inspection - Iat sensor removal/installation - Ect sensor inspection - Ect sensor removal/installation - To sensor inspection - To sensor removal/installation - Ho2 sensor inspection (for e-02, 19, 24) - Ho2 sensor removal/installation 06 FUEL SYSTEM AND THROTLE BODY - Fuel delivery system - Fuel system - Fuel tank removal - Fuel tank installation - Fuel pressure inspection - Fuel pump inspection - Fuel discharge amount inspection - Fuel pump relay inspection - Fuel pump removal and disassembly - Fuel mesh filter inspection and cleaning - Fuel pump reassembly and installa-tion - Throttle body - Construction - Air cleaner box removal - Air cleaner box installation - Throttle body removal - Throttle body disassembly - Throttle body cleaning - Inspection - Throttle body reassembly - Throttle body installation - Stp sensor adjustment - Fuel injector removal - Fuel injector inspection - Fuel injector installation - Fast idle - Fast idle adjustment - Throttle valve synchronization - Throttle position sensor (tps) setting 07 COOLING AND LUBRICATION SYSTEM - Engine coolant - Cooling circuit - Cooling circuit inspection - Radiator and water hoses - Radiator removal - Radiator cap inspection - Radiator inspection and cleaning - Radiator remounting - Water hose and reservoir tank inspection - Cooling fan - Inspection - Removal - Installation - Cooling fan thermo-switch - Removal - Inspection - Installation - Engine coolant temperature sensor - Removal - Inspection - Installation - Thermostat - Removal - Inspection - Installation - Water pump - Removal and disassembly - Inspection - Reassembly and installation - Lubrication system - Oil pressure - Oil filter - Oil pressure regulator - Oil strainer - Oil jet - Oil pump - Oil pressure switch - Engine lubrication system chart 08 CHASSIS - Exterior parts - Removal - Remounting - Front wheel - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Front fork - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Handlebar - Construction - Removal and disassembly - Reassembly and remounting - Steering - Construction - Removal and disassembly - Inspection and disassembly - Reassembly and remounting - Steering tension adjustment - Rear wheel - Construction - Removal - Disassembly - Inspection and disassembly - Reassembly and remounting - Rear suspension - Construction - Removal - Inspection and disassembly - Reassembly - Remounting - Rear shock absorber disposal - Suspension setting - Front brake - Construction - Brake pad replacement - Brake fluid replacement - Brake caliper removal and disassembly - Brake caliper inspection - Brake caliper reassembly and remounting - Brake disc inspection - Master cylinder removal and disassembly - Master cylinder inspection - Master cylinder reassembly and remounting - Rear brake - Construction - Removal and disassembly - Inspection - Reassembly and remounting - Rear brake rod - Reassembly remounting - Tire and wheel - Tire removal - Inspection - Valve inspection - Tire installation - Balancer weight installation 09 ELECTRICAL SYSTEM - Cautions in servicing - Connector - Coupler - Clamp - Fuse - Semi-conductor equipped part - Battery - Connecting the battery - Wiring procedure - Using the multi-circuit tester - Location of electrical components - Charging system - Troubleshooting - Inspection - Starter system and side-stand/ignition interlock system - Troubleshooting - Starter motor removal and disassembly - Starter motor inspection - Starter motor reassembly - Starter relay inspection - Side stand/ignition interlock system parts inspection - Ignition system - Troubleshooting - Inspection - Speedometer and pilot lamp box - Description - Speedometer removal and disassembly - Pilot lamp box removal and disassembly - Inspection - Lamps - Headlight, brake light/taillight, license plate light and turn signal light - Relays - Turn signal/side-stand relay - Starter relay - Fuel pump relay - Switches - Battery - Specifications - Initial charging - Servicing - Recharging operation 10 SERVICING INFORMATION - Troubleshooting - Fi system malfunction code and defective condition - Engine - Radiator (cooling system) - Chassis - Shaft drive - Brakes - Electrical - Battery - Wiring harness, cable and hose routing - Wiring harness routing - Cable routing - Throttle body installation - Cooling system hose routing - Front brake routing - Speed sensor harness routing - Front turn signal installation - Front turn signal lead wire routing - Muffler & exhaust pipe installation - Handlebar balancer - Battery protector - Lubrication points - Fuel tank installation - Rear combination lamp installation - Frame head cover cushion installation - Left side cover cushion installation - Rear fender cushion installation - Left side cover installation - Lid cushion instsallation - Tail lamp installation - Pair (air supply) system diagram - Pair (air supply) system hose routing - Special tools - Tightening torque - Engine - Secondary and final - Fi system and intake air system - Cooling system - Chassis - Tightening torque chart - Service data 11 EMISSION CONTROL INFORMATION - Emission control systems - Fuel injection system - Exhaust emission control system (pair system) - Noise emission control system - Evaporative emission control system (only for e-33) - Pair (air supply) system inspection - Hoses - Pair reed valve - Pair control solenoid valve - Pair (air supply) system hose routing - Heated oxgen sensor (ho2s) inspection (for e-02, 19, 24) - Evaporative emission control system inspection (only for e-33) - Hoses (evap hose) - Evap canister - Evap canister hose routing (only for e-33) 12 VZ800K6 ('06 MODEL) - Specifications - Service data - Exhaust emission control system (pair system) 13 VZ800K7 ('07 MODEL) & VZ800K8 ('08 MODEL) - Specifications - Service data - Fuel pump and fuel level gauge removal - Fuel pump and fuel level gauge installation - Speedmeter and pilot lamp box inspection - Fuel level meter inspection - Fuel level gauge inspection - Switches - Front brake hose routing - Wiring harness cable routing 14 VZ800K9 (’09-MODEL) - Abbreviations used in this manual - Sae-to-former suzuki term - Country and area codes - Specifications - Periodic maintenance schedule - Periodic maintenance chart - Maintenance and tune-up procedures - Air cleaner - Spark plug - Valve clearance - Engine oil and oil filter - Throttle cable play - Throttle valve synchronization - Evaporative emisson control system (e-33 only) - Fi system diagnosis - Fi system wiring diagram - Ecm terminal - Fail-safe function - Dtc table and defective condition - Dtc troubleshooting - Throttle body - Construction - Throttle body removal - Throttle body disassembly - Throttle body cleaning - Throttle body inspection - Throttle body reassembly - Throttle body installation - Stp sensor adjustment - Tp sensor adjustment - Isc valve removal - Isc valve installation - Isc valve inspection - Isc valve preset and opening initialization - Throttle valve synchronization - Ignition system - Inspection - Wiring harness routing - Cable routing - Speed sensor harness routing - Throttle body installation - Ignition coil installation - Engine mounting - Muffler & exhaust pipe installation - Pair (air supply) system hose routing - Special tools - Tightening torque - Engine - Service data - Emission control system - Exhaust emission control system (pair system) - Evaporative emission control system (only for e-33) - Pair (air supply) system inspection - Heated oxygen sensor (ho2s) inspection(for e-02, 19, 24, 33) - Evaporative emission control system inspection(only for e-33) - Evap system purge control solenoid valve - Fuel shut-off valve - Pair (air supply) system diagram - Pair (air supply) system hose routing - Evap canister hose routing (only for e-33) 15 WIRING DIAGRAM
Suzuki VZ800 Workshop Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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