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Suzuki Manuals
Motorcycle
1997 VZ800
Service manual
Suzuki 1997 VZ800 Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Group Index
Component Parts and Work to be Done
Symbol
General Information
Warning/Caution/Note
General Precautions
Serial Number Location
Fuel, Oil and Engine Coolant Recommendation
Engine Oil
Brake Fluid
Anti-Freeze/Engine Coolant
Liquid Amount of Water/Engine Coolant
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Dimensions and Dry Mass
Country or Area
Periodic Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Cleaning
Valve Clearance
Air Cleaner Element Remounting
Spark Plug
Engine Oil and Oil Filter
Fuel Hose
Carburetor
Engine Idle RPN
Returning Cable Play
Carburetor Synchronization
Clutch
Engine Coolant
Drive Chain
Carburettor Adjusting
Carburetor Cleaning and Lubricating
Front Brake
Brake Fluid Level
Brake Pads
Rear Brake
Air Bleeding the Brake Fluid Circuit
Brake Pedal Height and Free Travel
Tire Tread Condition
Tire Pressure
Brake Light Switch
Brake Shoe Wear
Steering
Front Fork
Rear Suspension
Exhaust Pipe Bolts
Chassis Bolts and Nuts
Compression Pressure Check
Compression Pressure Specifications
Compression Test Procedure
Low Compression Pressure
Oil Pressure Check
Oil Pressure Test Procedure
Low Oil Pressure
High Oil Pressure
Engine
Engine Components Removable with the Engine in Place
Engine Center
Engine Right Side
Engine Left Side
Engine Removal
Engine Reinstallation
Exhaust Gas Sealer
Engine Disassembly
Engine Components Inspection and Servicing
Cylinder Head Cover and Rocker Arm
Cylinder Head Cover Distortion
Rocker Arm Shaft O.D.
Camshaft
Camshaft Cam Wear
Camshaft Journal Wear
Cam Chain Tensioner and Guide
Camshaft Runout
Cylinder Head, Valve and Valve Spring
Valve and Valve Spring Disassembly
Cylinder Head Distortion
Valve Face Wear
Valve Stem Runout
Valve Head Radial Runout
Valve Stem Deflection
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width
Valve Seat Servicing
Valve Stem End Condition
Valve Spring
Valve and Valve Spring Reassembly
Cylinder and Piston
Cylinder Distortion
Cylinder Bore
Piston Diameter
Piston to Cylinder Clearance
Piston Ring to Groove Clearance
Piston Ring Free End Gap and End Gap
Piston Pin and Pin Bore
Oversize Piston Ring
Oversize Oil Ring
Oversize Side Rail
Conrod Small End I.D.
Conrod Big End Thrust Clearance
Conrod-Crank Pin Bearing Selection
Crank Pin Bearing Oil Clearance
Bearing Selection Table
Conrod I.D. Specification
Crank Pin O.D. Specification
Bearing Thickness
Conrod-Crank Pin Bearing Assembly
Crankcase-Crankshaft Bearing Selection
Crankshaft Thrust Clearance
Clutch Drive and Driven Plates
Clutch Spring Free Length
Clutch Bearing
Clutch Release Rack and Pinion
Generator Stator and Signal Generator Stator Inspection
Generator Stator and Signal
Starter Clutch Inspection
Oil Pump
Starter Clutch Servicing
Transmission Disassembly
Transmission Reassembly
Transmission Gears and Related Parts
Gear-Shifting Fork
Gear-Shifting Fork Clearance
Oil Jet and Nozzle
Engine Reassembly
Camshaft Timing
Fuel and Lubrication System
Fuel System
Fuel Pump Description
Starting Engine
After Start
Fuel Pump Removal
Fuel Pump Inspection
Wire Color
Fuel Tank and Fuel Valve
Fuel Valve Mechanism
Fuel Tank Removal
Fuel Filter Removal
Inspection and Cleaning
Carburetor Construction
I.D. No. Location
Diaphragm and Piston Operation
Slow System
Transient Enrichment System
Main System
Starter System
Float System
Carburetor Cleaning
Needle Valve Inspection
Fuel Level Inspection
Float Height Adjustment
Throttle Position Switch Inspection
Throttle Valve
Coasting Valve
Pilot Screw
Pilot Air Jet
Needle Jet
Pilot Jet, Main Jet and Valve Seat
Float Chamber
Piston Valve and Carburetor Top Gear
Starter Plunger
Throttle Cables
Carburetor Clamp
Pulling Cables
Returning Cable
Balance of Carburetors
Calibrating each Gauge
Engine Lubrication System Chart
Cooling System
Cooling System Description
Cooling System Construction
Radiator and Water Hoses Removal
Cooling System Inspection
Radiator Cap Inspection
Radiator Inspection and Cleaning
Water Hoses
Radiator Mounting Bolt and Clamp
Cooling Fam Removal
Cooling Fan Inspection
Cooling Fan Installation
Engine Coolant Temperature Switch
Water Pump
Water Pump Bearing
Mechanical Seal
Chassis
Exterior Parts
Frame Cover
Steering Head Cover
Front Wheel
Wheel Bearings
Front Axle
Brake Disc
Tire Removal
Wheel Inspection
Tire Inspection
Valve Inspection
Tire Installation
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Damper/Inner Tube
Outer Tube
Oil Seal
Fork Oil
Front Fork Remounting
Outer Races
Stem Nut
Steering Tension Adjustment
Rear Wheel and Brake
Rear Axle
Sprocket
Rear Sprocket Mounting Drum Bearing
Brake Shoe
Brake Drum
Wheel Bearing
Rear Brake Pedal
Rear Suspension and Swingarm
Swingarm Pivot Bearings
Shock Absorber
Swingarm Pivot Shaft
Chain Buffer
Swingarm Bearing
Rear Swingarm Pivot Nut
Rear Shock Absorber Bolt and Nut
Final Inspection and Adjustment
Rear Axle and Torque Link Nut
Suspension Setting
Electrical System
Cautions in Servicing
Connector
Coupler
Clamp
Battery
Connecting Battery
Using Multi Circuit Tester
Location of Electrical Components
Charging System Description
Function of Regulator
Electrical System Troubleshooting
Battery Runs down Quickly
Battery Leak Current Inspection
Charging Output Inspection
Generator Coil Continuity Inspection
Generator No-Load Performance Inspection
Regulator/Rectifier Inspection
Starter System Description
Side-Stand/Ignition Interlock System Description
Starter Motor will Not Run
Starter Motor Removal and Disassembly
Starter Motor Inspection
Carbon Brush
Starter Motor Reassembly
Commutator
Armature Coil Inspection
Oil Seal Inspection
Starter Relay Inspection
Starter Control Relay Inspection
Side-Stand/Ignition Interlock System Part Inspection
Diode
Neutral Switch
Side-Stand Switch
Side-Stand/Ignition Interlock Relay
Ignition System Description
Ignition System Troubleshooting
No Spark or Poor Spark
Ignition System Inspection
Ignition Coil Primary Peak Voltage
Ignition Coil
Ignition Coil Resistance
Signal Generator
Signal Generator Resistance
Speedometer and Instrument Panel
Lamps
Headlight
Bulb Replacement
Tail/Brake Light
Turn Signal Light
Starter Relay
Turn Signal Relay
Switches
Initial Charging
Filling Electrolyte
Recharging Operation
Wiring Diagram
Wire Harness Routing
Fuel System Hose Routing
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Table of
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Table of Contents
Troubleshooting
Electrical System Troubleshooting
211
Ignition System Troubleshooting
224
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This manual is also suitable for:
1998 vz800
1999 vz800
2000 vz800
2001 vz800
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