VZ800
99500-38050-01E
, FOREWORD
This manual contains an introductory description on
GROUP INDEX
the SUZUKI VZ800 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is GENERAL INFORMATION 1
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
PERIODIC MAINTENANCE 2
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 ENGINE 3
and reliable service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
SHAFT DRIVE 4
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle. FI SYSTEM 5
* Illustrations in this manual are used to show
the basic principles of operation and work
FUEL SYSTEM AND THROTTLE
procedures. They may not represent the
actual motorcycle exactly in detail. BODY
6
* This manual is written for persons who have
enough knowledge, skills and tools, including COOLING AND LUBRICATION
special tools, for servicing SUZUKI motorcy- SYSTEM
7
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you. CHASSIS 8
Inexperienced mechanics or mechanics ELECTRICAL SYSTEM 9
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
SERVICING INFORMATION 10
mechanic and may render the motorcycle
unsafe for the rider and passenger. EMISSION CONTROL
INFORMATION
11
WIRING DIAGRAM 12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
,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
1 Front axle 6 Brake disc
2 Bearing (R) 7 Spacer
3 Front wheel ITEM N·m kgf-m lb-ft
4 Spacer A Front axle A 65 6.5 47.0
5 Bearing (L) B Brake disc mounting bolt B 23 2.3 16.5
, 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.
Apply THREAD LOCK SUPER “1360”.
Data beside it indicates specified
99000-32130
torque.
Apply oil. Use engine oil unless other- Use engine coolant.
wise specified. 99000-99032-11X
Apply molybdenum oil solution.
Use fork oil.
(Mixture of engine oil and SUZUKl
99000-99044-L01
MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA) Apply or use brake fluid.
99000-25010 (Others)
Apply SUZUKI MOLY PASTE.
Measure in voltage range.
99000-25140
Apply SUZUKI SILICONE GREASE.
Measure in resistance range.
99000-25100
Apply SUZUKI BOND “1207B”.
Measure in current range.
99000-31140
Apply SUZUKI BOND “1216B”.
1216 Measure in diode test range.
99000-31230
Apply THREAD LOCK SUPER “1303”.
Measure in continuity test range.
99000-32030
Apply THREAD LOCK SUPER “1322”.
Use special tool.
99000-32110 (Except USA)
Apply THREAD LOCK “1342”.
Indication of service data.
99000-32050
99500-38050-01E
, FOREWORD
This manual contains an introductory description on
GROUP INDEX
the SUZUKI VZ800 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is GENERAL INFORMATION 1
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
PERIODIC MAINTENANCE 2
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 ENGINE 3
and reliable service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
SHAFT DRIVE 4
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle. FI SYSTEM 5
* Illustrations in this manual are used to show
the basic principles of operation and work
FUEL SYSTEM AND THROTTLE
procedures. They may not represent the
actual motorcycle exactly in detail. BODY
6
* This manual is written for persons who have
enough knowledge, skills and tools, including COOLING AND LUBRICATION
special tools, for servicing SUZUKI motorcy- SYSTEM
7
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you. CHASSIS 8
Inexperienced mechanics or mechanics ELECTRICAL SYSTEM 9
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
SERVICING INFORMATION 10
mechanic and may render the motorcycle
unsafe for the rider and passenger. EMISSION CONTROL
INFORMATION
11
WIRING DIAGRAM 12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
,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
1 Front axle 6 Brake disc
2 Bearing (R) 7 Spacer
3 Front wheel ITEM N·m kgf-m lb-ft
4 Spacer A Front axle A 65 6.5 47.0
5 Bearing (L) B Brake disc mounting bolt B 23 2.3 16.5
, 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.
Apply THREAD LOCK SUPER “1360”.
Data beside it indicates specified
99000-32130
torque.
Apply oil. Use engine oil unless other- Use engine coolant.
wise specified. 99000-99032-11X
Apply molybdenum oil solution.
Use fork oil.
(Mixture of engine oil and SUZUKl
99000-99044-L01
MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA) Apply or use brake fluid.
99000-25010 (Others)
Apply SUZUKI MOLY PASTE.
Measure in voltage range.
99000-25140
Apply SUZUKI SILICONE GREASE.
Measure in resistance range.
99000-25100
Apply SUZUKI BOND “1207B”.
Measure in current range.
99000-31140
Apply SUZUKI BOND “1216B”.
1216 Measure in diode test range.
99000-31230
Apply THREAD LOCK SUPER “1303”.
Measure in continuity test range.
99000-32030
Apply THREAD LOCK SUPER “1322”.
Use special tool.
99000-32110 (Except USA)
Apply THREAD LOCK “1342”.
Indication of service data.
99000-32050
