Suzuki VX800 L,M,N,P 90-93 Service Manual ENG By Mosue.pdf

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.

GENERAL INFORMATION

PERIODIC MAINTENANCE AND

TUNE-UP PROCEDURES

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.

ENGINE

SHAFT DRIVE

COOLING SYSTEM

IMPORTANT

FUEL AND LUBRICATION

SYSTEM

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.

1 ELECTRICAL SYSTEM

CHASSIS

SERVICING INFORMA T/ON

EMISSION CONTROL

INFORMA T/ON

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.

PROGRAM

MANUAL/SER-

VX800M (‘9 l-MODEL)

VX800N

(‘92~MODEL)

SUZUKI

MOTOR CORPORATION

Mo tort ycle Technical

Service Department

VX8OOP (‘93-MODEL)

0 COPYRIGHTSUZUKI

MOTOR CORPORATION 1990

VIEW OF SUZUKI VX8OOL

LEFT SIDE

RIGHT SIDE

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-

SPECIFICA TIONS

. . . .. . . . . .. .. . . . . .. . . . . .. . . . . .. . . . . .. . . .. . . . .. . . . . .. . . .. . .. .l_ g

COUNTRY OR AREA .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . .. .. . .. . . . . .1-11

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

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.

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/

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.

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 1 OW/40. If an SAE 1OW/40 motor

oil is not available, select an alternate according to the fol-

lowing chart.

MULTIGRADE

-30

-20-10

TEMP.

-22

-4

66 104

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.

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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