Suzuki VX800L Manuel utilisateur

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

Classic Cycles Technical Resources

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

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

Classic Cycles Technical Resources

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-

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.

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. <

-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.

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

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.

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

A”

For other models

SUZUKI BRAKE FLUID

DOT3 & DOT4

99000-23110

SUZUKI GOLDEN CRUISER

1200NA

99000-99032-10x

SUZUKI SUPER GREASE “A”

99000-25010

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

Brake pedal boss

Final driven gear spline and

O-ring

Swingarm spacer, bearing and

dust seal

PART

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1-5 GENERAL INFORMATION

MATERlAL PART

For U.S.A. model

PAGE

For other models

g g

Brakeca’iperax’e B-5

SUZUKI SILICONE GREASE

99000-25 100 SUZUKI SILICONE GREASE

99000-25100

Valve stem

Conrod big end bearing

Countershaft and driveshaft

Piston pin

Crankshaft journal bearing

Camshaft journal and cam face

Rocker arm and shaft

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

Oil pressure switch 3-17

& $&+y ;~~~~~t i

gear case

SUZUKI BOND NO. 1207B SUZUKI BOND NO. 1215

99104-31140 99000-311 IO

Cylinder head cover 3-60

@$zy @

SUZUKI BOND NO. 1216

99104-31160 SUZUKI BOND NO. 1216

99000-31160

Secondary driven bevel gear

housing bolt

Gearshift and stopper

Cam sprocket bolt

Final driven gear bearing

retainer screw

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

Generator stator mounting 3-41

screw

Generator lead wire guide 3-41

screw

Final gear case securing bolt 4-19

Starter motor housing screw 7-12

Front fork damper rod bolt 8-12

THREAD LOCK “1342”

99000-32050 THREAD LOCK “1342”

99000-32050

Oil pipe retainer bolt

Gearshift cam stopper bolt

Gearshift cam driven gear bolt

Gearshift cam guide nut and

paw1 lifter screw

Oil pump securing bolt

Brake pedal boss bolt

Front footrest bolt

3-45

3-49

3-50

3-51

8-25

8-39

THREAD LOCK SUPER THREAD LOCK SUPER

“1333B” “1 322”

99000-32020 99000-32 110

Crankcase bearing retainer

screw and bolt 3-18

THREAD LOCK SUPER “1303” THREAD LOCK SUPER “1324”

99000-32030 99000-32120

Brake disc mounting bolt 8-3

8-30

THREAD LOCK SUPER “1360” THREAD LOCK SUPER “1360”

99000-32 130 99000-32 130

Classic Cycles Technical Resources

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:

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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