Suzuki VX800 1990-1993 Service Manual 02 Periodic maintenance
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PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
LUBRICATION POINTS
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MAINTENANCE AND TUNE-UP PROCEDURES ..................2- 3
BATTERY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-
AIR CLEANERS
VALVE CLEARANCE
SPARK PLUGS
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ENGINE OIL AND OIL FILTER
FUEL LINES
CARBURETORS
COOLING SYSTEM
CLUTCH
FINAL GEAR OIL
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BRAKES
TIRES
STEERING
FRONT FORKS
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REAR SHOCK ABSORBERS
CHASSIS BOLTS AND NUTS
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PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions however,
it is not necessary for ensuring emission level compliance.
The chart below lists the recommended intervals for all the required periodic service work necessary
keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms
kilometer, miles and time for your convenience.
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PERIODIC MAINTENANCE CHART
INTERVALS: THIS INTERVAL SHOULD
JUDGED BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST.
Battery (Specific gravity of electrolyte)
Air cleaner elements
Radiator hoses
BE km
miles
months
1000
600 4000
2
Clean every 6000 km (4000 miles) and
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replace every 12000 km (7500 miles)
6000
12 24
12000
7500
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18000 24000
11000 15000
36 48
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Brake fluid
Brakes I I
Tires
Steering
Front forks
Rear shock absorbers
Chassis bolts and nuts
NOTE:
R = Replace,
= Inspect and adjust, clean, lubricate or replace as necessary
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T = Tighten,
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1
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T
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Replace every two vears
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1
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T T
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T T
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PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below.
q
Clutch lever holder and clutch cable
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El Side-stant pivot
and spring hook
q
Footrest
ElCenter stand pivot
and spring hook
phot
q :
Oil
ra
NOTE:
*
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dart or grime.
*
Lubricate exposed parts which are subject to rust, with oil or grease.
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PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
BATTERY
Inspect every 6000 km (4000 miles or 12 months).
Remove the seat.
Remove the battery 0 and then @ lead wires from the
battery terminals.
Remove the battery from the battery holder.
Check the electrolyte level and specific gravity. Add distilled
water, as necessary, to keep the surface of the electrolyte
above the MIN. level line but not above the MAX. level line.
For checking specific gravity, use a hydrometer to determine the charged condition.
09900-28403 : Hydrometer
Standard specific gravity : 1.28 at 20°C (68” F)
An S.G. reading of 1.22 (at 20°C) or under means that the
battery needs recharging. Remove the battery from the ma-
chine and charge it with a battery charger.
CAUTION:
Never charge a battery while still in the machine as damage
may result to the battery or regulator/rectifier.
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MAX.(UPPER)
MIN.(LOWER)
Hydrometer
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Charge at a maximum of 1.6 amps.
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To install the battery, reverse the procedure described above.
CAUTION:
When installing the battery lead wires, fix the @ lead first and
0 lead last.
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Make sure that the breather hose is tightly secured and
undamaged, and is routed as shown in the figure.
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4
AIR CLEANERS
Clean every 6000 km (4000 miles) and
replace every 12000 km (7500 miles).
Remove the seat, frame covers and fuel tank.
Remove the right and left side frame head covers (Photo A),
then remove the right and left air cleaner mounting screws
(Photo 9).
Disconnect the air cleaner drain hose from the front side air
cleaner case (Photo C).
Loosen the two clamp screws and disconnect the joint hose
from the carburetor, then rise up the front side air cleaner
assembly (Photo D).
Remove the four screws and pull out the front side air
cleaner element (Photo E).
Loosen the four screws and pull out the rear side air cleaner
element (Photo F).
Carefully use an air hose to blow the dust from the air
cleaner elements (Photo G).
CAUTION:
Always apply an air pressure on the outside of the air cleaner
elements. If air pressure is applied on the inside, dirt will be
forced into the pores of the cleaner element thus restricting
air flow through the cleaner element.
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Reinstall the cleaned elements or new ones in reverse order
of removal,
CAUTION:
If driving under dusty conditions, clean the air cleaner elements
more frequently. The surest way to accelerate engine wear is
to use the engine without the elements or to use ruptured
elements. Make sure that the air cleaners are in good condition
at all times. Life of the engine depends largely on these com-
ponents
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2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
VALVE CLEARANCE
inspect every
6000
km (4000 miles or 12 months).
Valve clearance also must be checked and adjusted when:
(1)
the valve mechanism is serviced, and
(2) the camshaft are disturbed by removing them for servicing.
Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power.
Check and adjust the clearance to the specification.
Valve clearance (when cold) : IN. & EX. 0.08 - 0.13 mm
(0.003 - 0.005 in)
NOTE:
* The clearance specification is for COLD state.
* Both intake and exhaust valves must be checked and adjust-
ed when the piston is at Top Dead Center (TDCI of the
compression stroke.
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Remove the seat and the fuel tank.
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Remove the following parts.
@ Front side air cleaner, carburetor and outlet tube
@Valve inspection caps
@ Generator cover plug
@Timing inspection plug
@Spark plugs
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