SUZUKI VL VOLUSIA User Manual

A-PDF Split DEMO : Purchase from www.A-PDF.com to remove the watermark

VL800

99500-38041-01E

FOREWORD

This manual contains an introductory description on the SUZUKI VL800 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

* This manual has been prepared on the basis

of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

SHAFT DRIVE

FUEL AND LUBRICATION SYSTEM

COOLING SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

IMPORTANT (For USA)

All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific imformation required to properly inspect and service VL800 in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN.

Overseas Service Department

EMISSION CONTROL INFORMATION

VL800K2 (’02-MODEL)

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE

LOOKING FOR:

1.The text of this manual is divided into sections.

2.The section titles are listed in the GROUP INDEX.

3.Holding the manual as shown at the right will allow you to find the first page of the section easily.

4.The contents are listed on the first page of each section to help find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

1 Front axle 2 Bearing (R) 3 Front wheel 4 Spacer 5 Bearing (L) 6 Brake disc 7 Spacer

A Front axle B Brake disc mounting bolt

ITEM N.m kgf.m lb-ft

A 65 6.5 47.0 B 23 2.3 16.5

SYMBOL (For USA)

Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required. Data beside it indicates specified torque.

Apply oil. Use engine oil unless otherwise specified.

Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE “A”. 99000-25030

Apply SUZUKI MOLY PASTE. 99000-25140

Apply SUZUKI BOND “1207B”. 99104-31140

Use engine coolant. 99000-99032-11X

Use fork oil. 99000-99001-SS8

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Apply SUZUKI BOND “1216”. 99104-31160

Apply THREAD LOCK SUPER “1303”. 99000-32030

Apply THREAD LOCK “1342”. 99000-32050

Apply THREAD LOCK SUPER “1360”. 99000-32130

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

SYMBOL (For the other countries)