Suzuki VZ800 Workshop Manual

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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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suzuki VZ800

WORKSHOP, SERVICE, REPAIR MANUAL

Suzuki VZ800 Workshop Manual