Suzuki VX800 1990-1993 Service Manual 01 General

FOREWORD

The SUZUKI VX800 has been developed as a new generation motorcycle. It is packed with highly advanced design concepts including a V-2 engine, a liquid cooling system, a new highly efficient combustion system (TSCC), a fully transistorized ignition system and a shaft drive mechanism.

Combined with precise control and easy handling the VX800 provides excellent performance and

outstanding riding comfort.

GENERAL INFORMATION

PERIODIC MAINTENANCE AND

TUNE-UP PROCEDURES

This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do- ti- yourself mechanics, will also find this manual an extremely useful repair guide. This manual contains the most up-to-date information at the time of publication.

The rights are reserved to update or make corrections to this manual at any time.

IMPORTANT

All street-legal SUZUKI motorcycles with engine displacement of 5Occ or greater are subject to Environmental Pro tee tion Agent y emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements.

specific information required to properly inspect and service VX800 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

VICE BULLETIN.

This manual includes

PROGRAM MANUAL/SER-

ENGINE

SHAFT DRIVE

COOLING SYSTEM

FUEL AND LUBRICATION SYSTEM

1 ELECTRICAL SYSTEM

CHASSIS

SERVICING INFORMA T/ON

EMISSION CONTROL INFORMA T/ON

VX800M (‘9

l-MODEL)

SUZUKI

0 COPYRIGHTSUZUKI MOTOR CORPORATION 1990

MOTOR CORPORATION

Mo tort ycle

Service Department

Technical

VX800N

(‘92~MODEL)

VX8OOP (‘93-MODEL)

VIEW OF SUZUKI VX8OOL

LEFT SIDE

RIGHT SIDE

CONTENTS

SERIAL NUMBER LOCA T/ON FUEL, OIL A ND

COOL

NT RECOMMENDA TION BREAK-IN PROCEDURES CYLINDER /DENT/FICA T/ON SPECIAL MATERIALS

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. . . . . . . . . . . . . . . . . . I- 1

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3 4

PRECAUTIONS AND GENERAL INSTRUCTIONS ..................l- 7

SPECIFICA TIONS COUNTRY OR AREA

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l-l GENERAL INFORMATION

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 0 is stamped on the steering head pipe. The engine serial number @ is located on the rear side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

FUEL, OIL AND COOLANT RECOMMENDATION

FUEL (For U.S.A. model)

1. Use only unleaded gasoline of at least 87 pump octane by F method or 91 octane or higher rated by the

the

Research method.

n Suzuki recommends that customers use alcohol-free, un-

leaded gasoline whenever possible. Use of blended gasoline containing MTBE (Methyl Tertiary

3. Butyl Ether) is permitted. Use of blended gasoline/alcohol fuel is permitted, provided

4. that the fuel contains not more than 10% ethanol. Gasoline/

alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.

5. If the performance of the vehicle is unsatisfactory while

using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline.

6. Failure to follow these guideline could possibly void appli-

cable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

FUEL (For Canadian model)

Use only unleaded gasoline of at least

v method or 91 octane or higher

method.

87 pump octane by the

rated by the Research

FUEL (For the other models)

Gasoline used should be graded 85 - 95 octane by the Research method or higher. An unleaded gasoline is recommended.

GENERAL INFORMATION 1-2

ENGINE OIL (For U.S.A. model)

Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the API

(American Petroleum Institute) classification system. The viscosity rating is SAE 1 OW/40. If an SAE 1 OW/40 motor oil is not available, select an alternate according to the fol-

lowing chart.

ENGINE OIL (For the other models)

Make sure that the engine oil you use comes under API clas-

sification of SE or SF and that its viscosity rating is SAE

1 OW/40. If an SAE 1 OW/40 motor oil is not available, select

an alternate according to the following chart.

MULTIGRADE

TEMP. <

-30 -20-10 0 10 20 30 40

-22 -4 14 32 50 68 66 104

GEAR OIL (FINAL DRIVE GEAR BOX)

Use SAE 90 hypoid gear oil which is rated GL-5 under API classification system. If you operate the

motorcycle where ambient temperature is below 0°C (32” F), use SAE 80 hypoid gear oil.

BRAKE FLUID

Specification and classification: DOT4

WARNING:

* Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer,

do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

* Do not use any brake fluid taken from old or used or unsealed containers.

* Never reuse brake fluid left over from a previous servicing, which has been stored for a long period.

FRONT FORK OIL

Use fork oil #lo.

COOLANT

Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distrilled water only.

WATER FOR MIXING

Use distrilled water only. Water other than distrilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/COOLANT

The coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the coolant should be

used at all times even though the atomospheric temperature in your area does not go down to freezing point.

Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200NA anti-freeze/coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

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