Suzuki VX800 1990-1993 Service Manual 06 Fuel and lubrication system
CONTENTS
FUEL SYSTEM
FUEL COCK
FUEL
CARBURETOR
PUMP
CARBURETOR CONSTRUCT/ON ................................
SPEC/F/CA T/ONS .....................................................
I.D. NO. LOCA T/ON
DIAPHRAGM AND PISTON OPERATION .....................6 - 8
SLOW SYSTEM
TRANSIENT ENRICHMENT SYSTEM...........................6 - 9
MAIN SYSTEM
STARTER SYSTEM
FLOAT SYSTEM
REMOVAL
.............................................................
.................................................................
................................................................
..............................................................
...................................................
..................................................... .6_
........................................................
.................................................. .6_11
..................................................... .6_11
..............................................................
6s
6- 2
.6.6_
.6-
.6_
6- 8
.6_fO
.6-Q
1
3
4
4
6
9
DISASSEMBL Y
NEEDLE VALVE INSPECTION
FLOAT HEIGHT ADJUSTMENT
REASSEMBLY AND REMOUNTING
BALANCING CARBURETORS
LUBRICATION SYSTEM
O/L PRESSURE. .............................
OlL FILTER ....................................
OIL SUMP FILTER
LUBRICATION SYSTEM CHART
........................................................
.......................
........................
...................................
......
......................... .6_13
......................... .6_14
...
.........
......
......................... .6_15
......................... .6_17
......................... .6_17
......................... .6_18
........................ ..6_18
......................... .6_19
.6-Q
.6_13
6-1 FUEL AND LUBRICATION SYSTEM
FUEL SYSTEM
A vacuum operated fuel pump is used to supply fuel from the fuel tank to the carburetor. The pump is
necessary as the fuel cock is mounted lower than the carburetor fuel bowl. In addition, the pump assures
an adequate supply of fuel to the engine under the steepest climbing conditions as well as while running
across rough terrain.
-
No. 2 carburetor
Fuel
Fuel pump
FUEL AND LUBRICATION SYSTEM 6-2
FUEL COCK
A valve is provided at the top of the fuel cock lever and can switch over to “OFF”, “ON” and “RES”.
With the valve “ON” (normal), the main passage opens. With the valve “OFF”, both holes close.
“ON” position
“RES” position
“ON”
WARNING:
Gasoline is very explosive. Extreme care must be taken.
Gaskets must be replaced with new ones to prevent fuel
leakage.
INSPECTION AND CLEANING
If the fuel strainer is dirty with sediment or rust, fuel will not
flow smoothly and loss in engine power may result. Clean the
fuel strainer with compressed air.
6-3 FUEL AND LUBRICATION SYSTEM
FUEL PUMP
Vacuum pulsations from the carburetor intake tract are used to operate the pump diaphragm. When
vacuum
pressure is applied, the spring forces the diaphragm back, pushing the fuel through the outlet to the
carburetor.
A series of check valves is used in the fuel flow route to allow the fuel to move in only one direction,
through the pump body.
is
applied to the diaphragm, fuel is drawn from the tank into the diaphragm’s chamber. As positive
Fuel from fuel cock
:ive
Negat
Fuel to carburetor
Positive
1
FUEL PUMP INSPECTION
In case of fuel leak at fuel pump or air leak into the fuel line,
check the following items:
* Broken diaphragm
* Malfunction of check valve
* Loose screws on fuel pump
If any defect is found, replace the fuel pump assembly with a
new one.
CARBURETOR
CARBURETOR CONSTRUCTION
FUEL AND LUBRICATION SYSTEM 6-4
No. 2 (FRO
INT) CARBURETOR
(‘$ Syncronizing cable
@ Throttle valve
@ Throttle valve shaft
return spring
0 Needle valve
@ Seal ring
@ Main jet
@ Main jet holder
8 Pilot jet
@$ Starter plunger
@ Balance screw
@$ Coasting valve
0 Fuel hose
@$ Breather hose
@ Carburetor top cap
@$ Piston valve spring
@ Jet needle stopper plate
@ Spacer
@ E-ring
@$ Jet needle
@ Washer
@$ Spring
@ Piston valve
@$ Needle jet
6-5 FUEL AND LUBRICATION SYSTEM
No. 1 (REAR) CARBURETOR
@ Fuel hose
@ Coasting valve
@ Drain screw
@ Gasket
@ Float pin
@ Float
0 Needle valve
@ Filter
@ Main jet
@ Needle valve stopper screw
0 Pilot jet
@ Balance screw
@ Throttle valve
@ Throttle stop screw
@ Throttle valve shaft
@I Throttle valve return spring
0 Pilot screw
$$ Starter plunger
@& Fartburetor top cap
IS on valve spring
@ Breather hose
@ Jet needle stopper plate
@ Spacer
@ E-ring
@ Jet needle
@ Washer
0 Spring
@$ Piston valve
@ Needle jet
SPECIFICATIONS
CARBURETOR CARBURETOR
ITEM
Carburetor type MIKUNI MIKUNI
Bore SIX
I.D. No.
Idle r/min.
Float height 27.7fl.Omm
Main jet
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet (P.J.)
By-pass (8.P.)
Pilot outlet
Valve seat
Starter jet
Pilot screw (P.S.)
Pilot air jet
Throttle cable play
Choke cable play
(M.A.J.)
(Th .V .)
(P.A.J.)
(M.J.)
(J.N.1
(N.J.)
(P.0.)
W.S.)
(G.S.1
I
BS36SS (No. 1)
1100f100r/min.
I1 -09 20.04 in)
1
0.8 mm x 2PCS 0.8 mm x 3 PCS
l-3/8 turns back l-l/B turns back
I
No.2: (2.0 mm)
(0.02 - 0.04 in)
(0.02 - 0.04 in)
SPECIFICATION
E-02.04. 15,21,25,28,34
BDS36SS (No. 2)
36 mm
45coo
9.1 f 1 .O mm
(0.36 f 0.04 in)
I
# 132.5
1 .B mm
5FlOB-3rd 5D49-3rd
P-4
#115
#47.5
0.8 mm
1.5 mm
#
25
(PRE-SET)
No.1
: (#
70). No.1
0.5 - 1 .O mm
0.5 - 1 .O mm
#I20
#40
1 .O mm
# 22.5
(PRE-SET)
1
No.2: (I .2 mm)
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: (#
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65).
I
Carburetor type MIKUNI
Bore size 36 mm
I.D. No.
Idle rlmin.
Float height
Main jet (M.J.)
Main air jet (M.A.J.) 1.8 mm
Jet needle
Needle iet
Throttle valve (Th.V.) #125
Pilot jet (P.J.)
By-pass
Pilot outlet
Valve seat (V.S.1 1.5 -Starter jet (G.S.)
7
Pilot screw (P.S.) (PRE-SE.1
Pilot air jet
Tlrr
Throttle cable play
Choke cable play
L
ITEM
I II,
FUEL AND LUBRICATION SYSTEM 6-6
SPECIFICATION
E-33
BS36SS (No. 1) BDS36SS (No. 2)
45C20
1200 + 50 rlmin.
27.7 * 1 .O mm
(1.09 f 0.04 in) (0.36 f 0.04 in)
# 132.5
(J.N.1
(N.J.)
(B.P.)
(P.0.)
(P.A.J.) No. 1:
5E73-1st
/
0.8 mm x 2PCS 0.8 mm x 3PCS
0.8 mm
7. ,” ,? ~___(
hln
,.“. &.
0.5 - 1 .O mm
(0.02 - 0.04 in)
0.5 - 1 .O mm
(0.02 - 0.04 in)
P-q
#Y
11,111
#
cl=
L<
r,
I
(#
65).
\L.U mm) No. 2: (1.2 mm)
MIKUNI
9.1 + 1 .O mm
#/f?L?.i
5D47-1 st
I
# 110
1 n--
I.” 11,111
# 22.5
(PRE-SET)
No. 1: (#65),
I
1
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P-7
#YU
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CARBURETOR
ITEM
Carburetor type MIKUNI MIKUNI
Bore size 36 mm
I.D. No.
Idle r/min.
Float height
Main jet (M.J.)
Main air iet
Jet needle
Needle jet (N.J.1
Throttle valve
Pilot iet
By-pass
Pilot outlet
Valve seat
Starter iet
(M.A.J.) 1.8 mm
(J.N.)
(Th .V .)
1P.J.)
(B.P.)
(P.0.) 0.8 mm 1.0 mm
(V.S.1
(G.S.)
BS36SS (No.
1200 + 50 rlmin.
27.7fl.Omm
(1.09 * 0.04 in) (0.36 * 0.04 in)
0.8 mm x 2PCS 0.8 mm x 3 PCS
SPECIFICATION
E-03
BDSSBSS (No. 2)
1)
45ClO
9.1 * 1 .O mm
# l3Z i # ir_‘? i
5E72-1 st 5D47-1 st
P-7
#I25 # 110
#Yi
1.5 mm
#25
#22.5
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#YU
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CARBURETOR
r‘
No. 2: (1.2 mm)
Throttle cable play 0.5 - 1 .O mm
Choke cable play
(0.02 - 0.04 in)
0.5 - 1 .O mm
(0.02 - 0.04 inl
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