Suzuki 2001 VZ800 Manuals

Manuals and User Guides for Suzuki 2001 VZ800. We have 1 Suzuki 2001 VZ800 manual available for free PDF download: Service Manual

Suzuki 2001 VZ800 Service Manual (314 pages)

Brand: Suzuki | Category: Motorcycle | Size: 54.89 MB

Group Index
2
Component Parts and Work to be Done
3
Symbol
4
General Information
5
Warning/Caution/Note
6
General Precautions
6
Serial Number Location
8
Fuel, Oil and Engine Coolant Recommendation
8
Engine Oil
9
Brake Fluid
9
Anti-Freeze/Engine Coolant
9
Liquid Amount of Water/Engine Coolant
9
Break-In Procedures
10
Cylinder Identification
10
Information Labels
11
Specifications
12
Dimensions and Dry Mass
12
Country or Area
14
Periodic Maintenance
15
Periodic Maintenance Schedule
16
Periodic Maintenance Chart
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Air Cleaner
18
Air Cleaner Element Removal
18
Air Cleaner Element Cleaning
18
Valve Clearance
19
Air Cleaner Element Remounting
19
Spark Plug
22
Engine Oil and Oil Filter
23
Fuel Hose
24
Carburetor
24
Engine Idle RPN
24
Returning Cable Play
24
Carburetor Synchronization
25
Clutch
25
Engine Coolant
25
Drive Chain
26
Carburettor Adjusting
27
Carburetor Cleaning and Lubricating
27
Front Brake
28
Brake Fluid Level
28
Brake Pads
28
Rear Brake
29
Air Bleeding the Brake Fluid Circuit
29
Brake Pedal Height and Free Travel
29
Tire Tread Condition
30
Tire Pressure
30
Brake Light Switch
30
Brake Shoe Wear
30
Steering
31
Front Fork
31
Rear Suspension
31
Exhaust Pipe Bolts
31
Chassis Bolts and Nuts
32
Compression Pressure Check
34
Compression Pressure Specifications
34
Compression Test Procedure
34
Low Compression Pressure
34
Oil Pressure Check
35
Oil Pressure Test Procedure
35
Low Oil Pressure
35
High Oil Pressure
35
Engine
36
Engine Components Removable with the Engine in Place
37
Engine Center
37
Engine Right Side
37
Engine Left Side
37
Engine Removal
38
Engine Reinstallation
44
Exhaust Gas Sealer
46
Engine Disassembly
47
Engine Components Inspection and Servicing
60
Cylinder Head Cover and Rocker Arm
60
Cylinder Head Cover Distortion
60
Rocker Arm Shaft O.D.
60
Camshaft
62
Camshaft Cam Wear
62
Camshaft Journal Wear
62
Cam Chain Tensioner and Guide
63
Camshaft Runout
63
Cylinder Head, Valve and Valve Spring
64
Valve and Valve Spring Disassembly
64
Cylinder Head Distortion
64
Valve Face Wear
64
Valve Stem Runout
65
Valve Head Radial Runout
65
Valve Stem Deflection
65
Valve Stem Wear
65
Valve Guide Servicing
66
Valve Seat Width
67
Valve Seat Servicing
67
Valve Stem End Condition
69
Valve Spring
69
Valve and Valve Spring Reassembly
69
Cylinder and Piston
71
Cylinder Distortion
71
Cylinder Bore
71
Piston Diameter
71
Piston to Cylinder Clearance
72
Piston Ring to Groove Clearance
72
Piston Ring Free End Gap and End Gap
72
Piston Pin and Pin Bore
73
Oversize Piston Ring
73
Oversize Oil Ring
73
Oversize Side Rail
73
Conrod Small End I.D.
74
Conrod Big End Thrust Clearance
74
Conrod-Crank Pin Bearing Selection
74
Crank Pin Bearing Oil Clearance
75
Bearing Selection Table
75
Conrod I.D. Specification
76
Crank Pin O.D. Specification
76
Bearing Thickness
76
Conrod-Crank Pin Bearing Assembly
77
Crankcase-Crankshaft Bearing Selection
77
Crankshaft Thrust Clearance
79
Clutch Drive and Driven Plates
80
Clutch Spring Free Length
80
Clutch Bearing
80
Clutch Release Rack and Pinion
81
Generator Stator and Signal Generator Stator Inspection
81
Generator Stator and Signal
81
Starter Clutch Inspection
81
Oil Pump
82
Starter Clutch Servicing
82
Transmission Disassembly
83
Transmission Reassembly
84
Transmission Gears and Related Parts
85
Gear-Shifting Fork
86
Gear-Shifting Fork Clearance
86
Oil Jet and Nozzle
86
Engine Reassembly
87
Camshaft Timing
104
Fuel and Lubrication System
110
Fuel System
111
Fuel Pump Description
112
Starting Engine
112
After Start
112
Fuel Pump Removal
113
Fuel Pump Inspection
113
Wire Color
113
Fuel Tank and Fuel Valve
114
Fuel Valve Mechanism
114
Fuel Tank Removal
114
Fuel Filter Removal
115
Inspection and Cleaning
115
Carburetor Construction
116
I.D. No. Location
119
Diaphragm and Piston Operation
120
Slow System
121
Transient Enrichment System
121
Main System
122
Starter System
123
Float System
123
Carburetor Cleaning
131
Needle Valve Inspection
131
Fuel Level Inspection
132
Float Height Adjustment
133
Throttle Position Switch Inspection
134
Throttle Valve
134
Coasting Valve
134
Pilot Screw
134
Pilot Air Jet
135
Needle Jet
135
Pilot Jet, Main Jet and Valve Seat
135
Float Chamber
136
Piston Valve and Carburetor Top Gear
136
Starter Plunger
136
Throttle Cables
137
Carburetor Clamp
137
Pulling Cables
137
Returning Cable
137
Balance of Carburetors
138
Calibrating each Gauge
139
Engine Lubrication System Chart
141
Cooling System
142
Cooling System Description
143
Cooling System Construction
144
Radiator and Water Hoses Removal
147
Cooling System Inspection
148
Radiator Cap Inspection
148
Radiator Inspection and Cleaning
149
Water Hoses
149
Radiator Mounting Bolt and Clamp
149
Cooling Fam Removal
150
Cooling Fan Inspection
151
Cooling Fan Installation
151
Engine Coolant Temperature Switch
153
Water Pump
154
Water Pump Bearing
156
Mechanical Seal
156
Chassis
160
Exterior Parts
161
Frame Cover
161
Steering Head Cover
161
Front Wheel
162
Wheel Bearings
163
Front Axle
164
Brake Disc
165
Tire Removal
166
Wheel Inspection
168
Tire Inspection
168
Valve Inspection
168
Tire Installation
169
Brake Pad Replacement
172
Brake Fluid Replacement
172
Caliper Removal and Disassembly
173
Caliper Inspection
174
Caliper Reassembly and Remounting
174
Brake Disc Inspection
175
Master Cylinder Removal and Disassembly
175
Master Cylinder Inspection
176
Master Cylinder Reassembly and Remounting
177
Damper/Inner Tube
181
Outer Tube
181
Oil Seal
181
Fork Oil
182
Front Fork Remounting
185
Outer Races
189
Stem Nut
189
Steering Tension Adjustment
190
Rear Wheel and Brake
191
Rear Axle
194
Sprocket
194
Rear Sprocket Mounting Drum Bearing
194
Brake Shoe
195
Brake Drum
195
Wheel Bearing
195
Rear Brake Pedal
197
Rear Suspension and Swingarm
199
Swingarm Pivot Bearings
201
Shock Absorber
201
Swingarm Pivot Shaft
201
Chain Buffer
202
Swingarm Bearing
202
Rear Swingarm Pivot Nut
202
Rear Shock Absorber Bolt and Nut
202
Final Inspection and Adjustment
203
Rear Axle and Torque Link Nut
203
Suspension Setting
203
Electrical System
204
Cautions in Servicing
205
Connector
205
Coupler
205
Clamp
205
Battery
206
Connecting Battery
206
Using Multi Circuit Tester
206
Location of Electrical Components
207
Charging System Description
209
Function of Regulator
209
Electrical System Troubleshooting
211
Battery Runs down Quickly
211
Battery Leak Current Inspection
212
Charging Output Inspection
212
Generator Coil Continuity Inspection
213
Generator No-Load Performance Inspection
213
Regulator/Rectifier Inspection
213
Starter System Description
214
Side-Stand/Ignition Interlock System Description
214
Starter Motor will Not Run
216
Starter Motor Removal and Disassembly
217
Starter Motor Inspection
217
Carbon Brush
217
Starter Motor Reassembly
218
Commutator
218
Armature Coil Inspection
218
Oil Seal Inspection
218
Starter Relay Inspection
219
Starter Control Relay Inspection
220
Side-Stand/Ignition Interlock System Part Inspection
221
Diode
221
Neutral Switch
221
Side-Stand Switch
222
Side-Stand/Ignition Interlock Relay
222
Ignition System Description
223
Ignition System Troubleshooting
224
No Spark or Poor Spark
224
Ignition System Inspection
225
Ignition Coil Primary Peak Voltage
225
Ignition Coil
226
Ignition Coil Resistance
226
Signal Generator
227
Signal Generator Resistance
228
Speedometer and Instrument Panel
229
Lamps
231
Headlight
231
Bulb Replacement
231
Tail/Brake Light
232
Turn Signal Light
233
Starter Relay
233
Turn Signal Relay
233
Switches
234
Initial Charging
235
Filling Electrolyte
235
Recharging Operation
237
Wiring Diagram
247
Wire Harness Routing
250
Fuel System Hose Routing
254
Cooling System Hose Routing
256
Pair (Air Supply) System Hose Routing
257
Front Brake Hose Routing
258
Special Tools
259
Tightening Torque
261
Tightening Torque Chart
263
Service Data
264
Vz800W
274
Vz800X/Y/K1
292
Engine Idle RPM (Idle Adjustment)
304
Exhaust Pipe and Muffler
304
Engine Side Box Set-Up
305
Evaporative Emission Control System
306
Evaporative Emission Control System Hose Routing
307
Evaporative Emission Control System Inspection
310
Carburetor Surge Control Valve
310

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Suzuki 2001 VZ800 Service Manual (314 pages)

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