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Intruder VZ800
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Suzuki VZ800 Manual
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Service manual
(454 pages)
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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
Engine Oil
Brake Fluid
Anti-Freeze/Engine Coolant
Liquid Amount of Water/Engine Coolant
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Country or Area
Periodic Maintenance
Lubrication Points
Maintenance and Tune up Procedures
Air Cleaner
Air Cleaner Element Removal
Valve Clearance
Air Cleaner Element Remounting
Spark Plug
Engine Oil and Oil Filter
Fuel Hose
Carburetor
Engine Idle RPM
Returning Cable Play
Carburetor Synchronization
Clutch
Engine Coolant
Drive Chain
Checking
Drive Chain Adjusting
Drive Chain Cleaning and Lubricating
Front Brake
Brake Fluid Level
Brake Pads
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 Specification
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
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
Camshaft Journal Oil Clearance
Cam Chain Tensioner and Guide
Cam Chain Tensioner
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 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
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
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 Servicing
Starter Clutch Inspection
Oil Pump
Starter Driven Gear Bearing Inspection
Starter Clutch Servicing
Transmission Disassembly
Transmission Gears and Related Parts
Gear-Shifting Fork Clearance
Oil Jey and Nozzle
Engine Reassembly
Location of Cylinder Head Bolt
Location of Cylinder Head Cover Bolt
Fuel and Lubrication System
Fuel System
Fuel Pump Description
Starting Engine
After Start
Fuel Pump Removal
Fuel Pump Inspection
Fuel Tank and Fuel Valve
Fuel Valve Mechanism
Fuel Tank Removal
Fuel Filter Removal
Carburetor Construction
Rear Carburetor
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
Reassembly and Remounting
Throttle Valve
Coasting Valve
Pilot Air Jet
Needle Jet
Pilot Jet, Main Jet and Valve Seat
Float Chamber
Piston Valve and Carburetor Top Cap
Starter Plunger
Throttle Cables
Carburetor Clamp
Pulling Cables
Returning Cable
Balance of Carburetors
Calibrating each Gauge
Lubrication System
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 Fan Removal
Cooling Fan Inspection
Cooling Fan Installation
Cooling Fan Thermo-Switch Removal
Cooling Fan Thermo-Switch Inspection
Cooling Fan Thermo-Switch Installation
Engine Coolant Temperature Switch Removal
Engine Coolant Temperature Switch Inspection
Engine Coolant Temperature Switch Installation
Water Pump Removal
Water Pump Bearing
Mechanical Seal
Chassis
Exterior Parts
Frame Cover
Steering Head Cover
Seat
Front Wheel Removal
Front Wheel Inspection and Disassembly
Speedometer Gearbox
Wheel Bearings
Front Axle
Brake Disc
Tire and Wheel
Tire Removal
Wheel Inspection
Tire Inspection
Valve Inspection
Valve Installation
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
Steering Inspection and Disassembly
Rear Wheel and Brake
Rear Axle
Wheel Damper
Sprocket
Brake Shoe
Brake Drum
Rear Sprocket Mounting Drum Bearing
Rear Brake Pedal
Rear Suspension and Swingarm
Swingarm Pivor Bearings
Shock Absorber
Swingarm Pivot Shaft
Chain Buffer
Swingarm Bearing
Rear Swingarm Pivot Nut
Final Inspection and Adjustment
Rear Axle and Torque Link Nut
Suspension Setting
Electrical System
Cautions in Servicing
Connector
Coupler
Clamp
Connecting Battery
Using Multi Circuit Tester
Location of Electrical Components
Charging System Description
Function of Regulator
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
No Spark or Poor Spark
Ignition Coil Primary Peak Voltage
Ignition Coil Resistance
Signal Generator
Signal Generator Resistance
Speedometer and Instrument Panel Removal and Disassembly
Lamps
Headlight
Bulb Replacement
Tail/Brake Light
Turn Signal Light
Starter Relay
Turn Signal Relay
Switches
Battery Specifications
Initial Charging
Filling Electrolyte
Recharging Operation
Servicing Information
Wiring Diagram
Wire Harness Routing
Cable Routing
Fuel System Hose Routing
Cooling System Hose Routing
Pair (Air Supply) System Hose Routing
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Service Manual
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