Suzuki VL800 Service Manual page 269

Complaint
Engine is noisy.
Clutch drags.
Transmission will not
shift.
Transmission will not
shift back.
Symptom and possible causes
Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn camshaft.
4. Worn or burnt camshaft journal.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon buildup in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain tensioner.
Noise seems to come from the clutch
1. Worn countershaft spline.
2. Worn clutch hub spline.
3. Worn clutch plate teeth.
4. Distorted clutch plate.
5. Weak clutch damper.
6. Weak clutch spring.
Noise seems to come from the crankshaft
1. Rattling bearing.
2. Worn or burnt crank pin bearing.
3. Worn or burnt journal bearing.
4. Excessive thrust clearance.
Noise seems to come from the transmission
1. Worn or rubbing gear.
2. Worn countershaft spline.
3. Worn driveshaft spline.
4 Worn or rubbing primary gear.
5. Worn bearing.
1. Clutch out of adjustment.
2 Clutch release screw out of adjustment.
3. Some clutch springs are weak, while others are not.
4. Worn or distorted clutch pressure plate.
5. Distorted clutch plate.
1. Broken gearshift cam.
2. Distorted gearshift fork.
3. Worn gearshift pawl.
1. Broken gearshift shaft return spring.
2. Rubbing or stuck gearshift shaft.
3. Worn or distorted gearshift fork.
SERVICING INFORMATION 9-3
Remedy
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Replace cam chain and
sprockets.
Replace cam chain and
sprockets.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace thrust bearing.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Adjust.
Adjust.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.