Suzuki VZ800K5 Manuals

Manuals and User Guides for Suzuki VZ800K5. We have 1 Suzuki VZ800K5 manual available for free PDF download: Service Manual

Suzuki VZ800K5 Service Manual

Suzuki VZ800K5 Service Manual (454 pages)

Brand: Suzuki | Category: Motorcycle | Size: 23.13 MB

Table of Contents

General Information 1

8
- General Information
  2
- Periodic Maintenance
  2
- Electrical System
  2
- Servicing Information
  2
- General Precautions
  9
- Suzuki Vz800K5 ('05-Model)
  11
  - Engine Oil
    12
  - Brake Fluid
    12
  - Front Fork Oil
    12
- Serial Number Location
  11
- Fuel, Oil and Engine Coolant Recommendation
  11
- Cylinder Identification
  13
- Information Labels
  14
  - Specifications
    15
  - Dimensions and Dry Mass
    15
  - Drive Train
    15
Chassis

16
- Periodic Maintenance Schedule
  18
  - Periodic Maintenance Chart
    18
  - Lubrication Points
    19
- Maintenance and Tune-Up Procedures
  20
  - Air Cleaner
    20
  - Spark Plug
    21
  - Valve Clearance
    23
  - Fuel Hose
    26
  - Engine Oil Replacement
    27
  - Engine Oil and Oil Filter
    27
  - Engine Idle Speed
    29
  - Throttle Cable Play
    30
  - Throttle Valve Synchronization
    31
  - Evaporative Emisson Control System (for E-33 Only)
    31
  - Pair (Air Supply) System
    31
  - Clutch
    32
  - Cooling System
    33
  - Engine Coolant Level Check/Change
    33
  - Final Gear Oil
    35
  - Brake
    35
  - Tire
    39
  - Steering
    39
  - Tire Tread Depth
    39
  - Front Fork
    40
  - Rear Suspension
    40
  - Exhaust Pipe Bolt
    40
  - Chassis Bolt and Nut
    41
- Compression Pressure Check
  43
  - Compression Test Procedure
    43
- Oil Pressure Check
  44
- Oil Pressure Test Procedure
  44
- Sds Check
  45
Engine

47
- Engine Components Removable with Engine in Place
  48
- Engine Removal and Installation
  49
  - Engine Removal
    49
  - Engine Installation
    54
  - Engine Disassembly
    57
- Engine Components Inspection and Servicing
  73
  - Cylinder Head Cover
    73
  - Camshaft
    74
  - Cam Chain Tensioner and Guide
    76
  - Cylinder Head
    76
  - Cylinder
    86
  - Piston
    87
    
    Piston Diameter
    87
    
    Piston Ring Groove Width
    87
    
    Piston Ring Thickness
    87
    
    Piston Ring End Gap
    88
  - Conrod/Crankshaft
    90
  - Clutch
    99
  - Generator/Signal Generator/ Starter Clutch
    100
  - Oil Pump
    102
  - Transmission
    103
  - Gearshift Fork
    106
  - Oil Jet
    106
  - Crankcase
    107
- Engine Reassembly
  111
Shaft Drive

133
- Secondary Bevel Gears
  134
  - Construction
    134
  - Removal
    136
  - Disassembly
    136
  - Inspection
    137
  - Secondary Gear Shims Adjustment
    138
  - Reassembly
    142
  - Installation
    142
- Final Bevel Gears
  143
  - Construction
    143
  - Final Gear Case Removal
    145
  - Final Gear Case Disassembly
    145
  - Final Gear Shims Adjustment
    149
  - Final Gear Case Reassembly
    153
  - Final Gear Case Installation
    157
Fi System

158
- Precautions in Servicing
  160
  - Connector/Coupler
    160
  - Fuse
    161
  - Ecm/Various Sensors
    161
  - Electrical Circuit Inspection Procedure
    163
  - Using the Multi-Circuit Tester
    166
- Fi System Technical Features
  167
- Fi System Parts Location
  169
  - Fi System Wiring Diagram
    171
- Ecm Terminal
  172
- Self-Diagnosis Function
  173
  - User Mode
    173
  - Dealer Mode
    174
  - Tps Adjustment
    176
- Fail-Safe Function
  177
- Fi System Troubleshooting
  178
- C32" (P0201) or "C33" (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
  223
- C41" (P0230) Fp Relay Circuit Malfunction
  225
- C42" (P01650) Ig Switch Circuit Malfunction
  225
- C44" (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (for E-02, 19, 24)
  226
- C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction
  230
- Iap Sensor Inspection
  232
- Iap Sensor Removal/Installation
  232
- Sensors
  232
- Tp Sensor Inspection
  232
- Tp Sensor Removal/Installation
  232
- Ckp Sensor Inspection
  233
- Ckp Sensor Removal/Installation
  233
- Stp Sensor Inspection
  233
- Stp Sensor Removal/Installation
  233
- Ect Sensor Inspection
  234
- Ect Sensor Removal/Installation
  234
- Iat Sensor Inspection
  234
- Iat Sensor Removal/Installation
  234
- To Sensor Inspection
  234
- To Sensor Removal/Installation
  234
- Ho2 Sensor Inspection (for E-02, 19, 24)
  235
- Ho2 Sensor Removal/Installation
  235
Fuel System and Throtle Body

236
- Fuel Delivery System
  237
- Fuel System
  238
  - Fuel Tank Removal
    238
  - Fuel Tank Installation
    238
  - Fuel Pressure Inspection
    239
  - Fuel Pump Inspection
    240
  - Fuel Discharge Amount Inspection
    240
  - Fuel Pump Relay Inspection
    241
  - Fuel Pump Removal and Disassembly
    242
  - Fuel Mesh Filter Inspection and Cleaning
    246
  - Fuel Pump Reassembly and Installation
    246
- Throttle Body
  247
  - Construction
    247
  - Air Cleaner Box Removal
    248
  - Air Cleaner Box Installation
    248
  - Throttle Body Removal
    248
  - Throttle Body Disassembly
    249
  - Throttle Body Cleaning
    252
  - Inspection
    252
  - Throttle Body Reassembly
    252
  - Throttle Body Installation
    255
  - Stp Sensor Adjustment
    256
  - Fuel Injector Removal
    256
  - Fuel Injector Inspection
    256
  - Fuel Injector Installation
    257
  - Fast Idle
    257
  - Fast Idle Adjustment
    257
  - Throttle Valve Synchronization
    259
  - Throttle Position Sensor (Tps) Setting
    260
Cooling and Lubrication System

261
- Engine Coolant
  262
- Cooling Circuit
  263
  - Cooling Circuit Inspection
    263
- Radiator and Water Hoses
  264
  - Radiator Removal
    264
  - Radiator Cap Inspection
    265
  - Radiator Inspection and Cleaning
    265
  - Radiator Remounting
    265
  - Water Hose and Reservoir Tank Inspection
    266
- Cooling Fan
  267
  - Inspection
    267
  - Removal
    267
  - Installation
    268
- Cooling Fan Thermo-Switch
  269
  - Removal
    269
  - Inspection
    269
  - Installation
    269
- Engine Coolant Temperature Sensor
  270
  - Removal
    270
  - Inspection
    270
  - Installation
    271
- Thermostat
  272
  - Removal
    272
  - Inspection
    272
  - Installation
    273
- Water Pump
  274
  - Removal and Disassembly
    274
  - Inspection
    275
  - Reassembly and Installation
    276
- Lubrication System
  279
  - Oil Pressure
    279
  - Oil Filter
    279
  - Oil Pressure Regulator
    279
  - Oil Strainer
    279
  - Oil Jet
    279
  - Oil Pump
    279
  - Oil Pressure Switch
    279
  - Engine Lubrication System Chart
    280
Chassis

281
- Exterior Parts
  283
  - Removal
    283
  - Remounting
    284
- Front Wheel
  285
  - Construction
    285
  - Removal and Disassembly
    287
  - Inspection
    288
  - Reassembly and Remounting
    289
- Front Fork
  292
  - Construction
    292
  - Removal and Disassembly
    293
  - Inspection
    296
  - Reassembly and Remounting
    297
- Handlebar
  301
  - Construction
    301
  - Reassembly and Remounting
    302
  - Removal and Disassembly
    302
- Steering
  304
  - Construction
    304
  - Removal and Disassembly
    305
  - Inspection and Disassembly
    307
  - Reassembly and Remounting
    307
  - Steering Tension Adjustment
    310
- Rear Wheel
  311
  - Construction
    311
  - Removal
    313
  - Disassembly
    314
  - Inspection and Disassembly
    315
  - Reassembly and Remounting
    316
- Rear Suspension
  318
  - Construction
    318
  - Removal
    320
  - Inspection and Disassembly
    323
  - Reassembly
    325
  - Remounting
    326
  - Rear Shock Absorber Disposal
    329
  - Suspension Setting
    329
- Chassis
  
  330
  - Front Brake
    330
    
    Construction
    330
    
    Brake Pad Replacement
    332
    
    Brake Caliper Removal and Disassembly
    333
    
    Brake Fluid Replacement
    333
    
    Brake Caliper Inspection
    334
    
    Brake Caliper Reassembly and Remounting
    335
    
    Brake Disc Inspection
    336
    
    Master Cylinder Removal and Disassembly
    337
    
    Master Cylinder Inspection
    338
    
    Master Cylinder Reassembly and Remounting
    339
  - Rear Brake
    341
    
    Construction
    341
    
    Inspection
    342
    
    Removal and Disassembly
    342
    
    Reassembly and Remounting
    343
    
    Rear Brake Rod
    344
    
    Reassembly Remounting
    345
    
    Inspection
    346
    
    Tire and Wheel
    346
    
    Tire Removal
    346
    
    Valve Inspection
    347
    
    Tire Installation
    348
    
    Balancer Weight Installation
    349
Electrical System

350
- Cautions in Servicing
  352
  - Clamp
    352
  - Connector
    352
  - Coupler
    352
  - Fuse
    352
  - Battery
    353
  - Connecting the Battery
    353
  - Semi-Conductor Equipped Part
    353
  - Wiring Procedure
    353
  - Using the Multi-Circuit Tester
    354
- Location of Electrical Components
  355
- Charging System
  357
  - Troubleshooting
    357
  - Inspection
    358
- Starter System and Side-Stand/Ignition Interlock System
  361
  - Troubleshooting
    361
  - Starter Motor Removal and Disassembly
    363
  - Starter Motor Inspection
    364
  - Starter Motor Reassembly
    364
  - Starter Relay Inspection
    365
  - Side Stand/Ignition Interlock System Parts Inspection
    366
- Electrical
  
  369
  - Spark Plug
    369
  - Battery
    369
  - Fuse
    369
    
    Ignition System
    369
    
    Troubleshooting
    369
    
    Inspection
    371
    
    Description
    374
    
    Speedometer and Pilot Lamp Box
    374
    
    Speedometer Removal and Disassembly
    375
    
    Pilot Lamp Box Removal and Disassembly
    377
    
    Inspection
    378
  - Brake Light/Taillight
    382
    
    Headlight, Brake Light/Taillight, License Plate Light and Turn Signal Light
    382
    
    Lamps
    382
    
    Fuel Pump Relay
    384
    
    Relays
    384
    
    Starter Relay
    384
    
    Switches
    384
    
    Turn Signal/Side-Stand Relay
    384
    
    Battery
    386
    
    Initial Charging
    386
    
    Specifications
    386
    
    Recharging Operation
    388
    
    Servicing
    388
  - 21 W
    382
Servicing Information

389
- Troubleshooting
  390
  - Fi System Malfunction Code and Defective Condition
    390
  - Engine
    393
  - Radiator (Cooling System)
    398
  - Chassis
    399
  - Shaft Drive
    400
  - Brakes
    400
  - Electrical
    401
  - Battery
    402
- Wiring Harness, Cable and Hose Routing
  403
  - Wiring Harness Routing
    403
  - Cable Routing
    406
  - Throttle Body Installation
    407
  - Cooling System Hose Routing
    408
  - Front Brake Routing
    409
  - Speed Sensor Harness Routing
    410
  - Front Turn Signal Installation
    410
  - Front Turn Signal Lead Wire Routing
    411
  - Muffler & Exhaust Pipe Installation
    411
  - Handlebar Balancer
    412
  - Battery Protector
    412
  - Lubrication Points
    413
  - Fuel Tank Installation
    414
  - Rear Combination Lamp Installation
    415
  - Frame Head Cover Cushion Installation
    416
  - Left Side Cover Cushion Installation
    416
  - Rear Fender Cushion Installation
    417
  - Left Side Cover Installation
    418
  - Lid Cushion Instsallation
    419
  - Tail Lamp Installation
    420
- Pair (Air Supply) System Diagram
  421
- Pair (Air Supply) System Hose Routing
  422
- Special Tools
  423
- Tightening Torque
  427
  - Engine
    427
  - Secondary and Final
    428
  - Fi System and Intake Air System
    428
  - Cooling System
    428
  - Chassis
    429
  - Tightening Torque Chart
    430
- Service Data
  431
- High Beam Indicator Light
  438
- Neutral Indicator Light
  438
- Speedometer Light
  438
- Turn Signal Indicator Light
  438
Emission Control Information

441
- Emission Control Systems
  
  442
- Pair (Air Supply) System Inspection
  
  445
  - Hoses
    445
  - Pair Reed Valve
    445
  - Pair Control Solenoid Valve
    446
- Pair (Air Supply) System Hose Routing
  
  447
- Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)
  
  448
- EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
  
  449
  - Only for E
    449
  - HOSES (EVAP Hose)
    449
  - Evap Canister
    449
- EVAP CANISTER HOSE ROUTING (Only for E-33)
  
  450

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