Suzuki VX800 1990-1993 Service Manual
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 7
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 3
CABLE, HARNESS AND HOSE ROUTING. . . . . . . . 11-15
II-I VXEOOM ('91-MODEL)
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Seat height
Dry
mass
ENGINE
Type .....................................
Valve clearance
Number of cylinders
.....................................
Bore
Stroke
Piston displacement
Compression ratio
Carburetor, Front.
Air cleaner
Starter system
Lubrication system
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Rear
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..
2280 mm (89.8 in).
2355
mm (92.7 in)
2265 mm
2255
805 mm (31.7 in)
1115 mm (43.9 in)
1085 mm (42.7 in)
1565 mm (61.6 in)
1555 mm
145 mm ( 5.7 in)
800 mm (31.5 in)
795 mm (31.3 in)
214 kg
213 kg
Four-stroke, water-cooled, OHC, TSCC, 45” V-twin
0.08 - 0.13 mm (0.003 - 0.005 in)
2
83.0 mm (3.268 in)
74.4 mm (2.929 in)
805 cm3 (49.12 cu. in)
10.0 : 1
Ml KUNI BDS36SS, single
Ml KUNI BS36SS,
Non woven fabric element
Electric starter motor
Wet sump
mm
........
(88.8
in)
(61.2
in)
(4721bs).
(470 Ibs)
E15,16,17,22,25,39
...
El8
..E03,3 3
Others
...
...
E03,28,33
Others
...
...
E03,33
Others
...
...
EOl, 03,28,33
Others
...
..
E33
...
Others
single
-
TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary reduction ratio
Gear ratios, Low
Secondary reduction ratio
Final reduction ratio
Drive system
...................................
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........................... 1
...........................
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2nd
............................
3rd
............................
4th
...........................
Top
........................
...............................
......................
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Wet
multi-plate type
5-speed
-down,
1.690 (71/42)
2.285 (32/14)
1.631 (31/19)
1.227 (27/22)
1 .OOO (25/25)
0.851 (23/27)
1.133 (17/15 x 30/30)
1.096 (17/15x 30/31)
3.090 (34/l 1)
Shaft drive
constant mesh
~-UP
...
...
E03,33
Others
CHASSIS
Front suspension
Rear suspension
Front suspension stroke
Rear wheel travel.
Caster ....................................
.....................................
Trail
Steering angle
Turning radius.
Front brake.
Rear brake.
Front tire size
Rear tire size.
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.............................. 35” (right & left)
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VXBOOM (‘91-MODEL) 11-2
Telescopic, coil spring, oil damped
Swingarm, coil spring, gas/oil damped,
spring preload 5-way adjustable;
rebound damping force 4-way adjustable
... EOl, 03, 28, 33;
compression damping force 4-way adjustable and
rebound damping force 4-way adjustable
150 mm (5.9 in)
118 mm (4.6 in)
119 mm (4.7 in)
59”
143 mm (5.63 in)
129 mm
142 mm (5.59 in)
3.2 m (10.5 ft)
Disc
Disc
110/80-18 58H, tubeless
150/70-l 7 69H, tubeless
150/70B-17 69H, tubeless
... E03,33
... EOl, 03, 28, 33
... Others
EOl, 28,
...
... Others
... E03,28,33
... Others
... Others
ELECTRICAL
Ignition type
Ignition timing
Sparkplug ................................
Battery
.....................................
Fuse
Headlight
Position light
Turn signal light
Tail/Brake light
License plate light
Speedometer light
Tachometer light
Neutral indicator light
High beam indicator light
Turn signal light indicator light
Oil pressure indicator light
Coolant ‘temperature check light
Speedometer light
Tachometer light
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Fully transistorized
5” B.T.D.C. below 1650 r/min and
30” B.T.D.C. above 3500 r/min
5” B.T.D.C. below 1625 r/min. and
35” B.T.D.C. above 3500 r/min
5” B.T.D.C. below 1625 r/min and
32” B.T.D.C. above 3750 r/min
NGK DPR8EA-9 or NIPPON DENS0 X24EPR-U9
12V 57.6 kC (lGAh)/lOHR
25/10/10/10A
12V 60/55W
12V 4W
12V 21W
12V 5/21W
12V 5W
12V 3.4W
12V 1.7W
12V 3.4W
12V 1.7W
12V 3.4W
12V 3.4W
12V 3W
12V 3.4W
12V 1.7W (x2pcs.l
...
except E03,28,33
... E03, 33
...
E-l 8
... Others
11-3 VXBOOM (‘91-MODEL)
SERVICE DATA
VALVE + GUIDE
Unit: mm (in)
-
Valve spring tension
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
IN.
EX.
12.09-13.91 k
STANDARD
35.954-35.994
(1.4155-1.4171)
36.919-36.959
(I .4535- 1.4551)
0.032-0.066
(0.0013-0.0026)
Unit: mm (in)
LIMIT
35.660
(I .4039)
36.620
(I .4417)
0.150
(0.0059)
VXBOOM (‘9%MODEL) 11-4
ITEM
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain 20-pitch length
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
No.1 Left side
No.2 Right side
No. 1 Right side
No.2 Left side
No. 1 Left side
No.2 Right side
No.1 Right side 24.959-24.980
No.2 Left side
IN. & EX.
IN. & EX.
STANDARD
20.012-20.025
(0.7879-0.7884)
25.012-25.025
(0.9847-0.9852)
19.959- 19.980
(0.7858-0.7866)
(0.9826-0.9835)
12.000- 12.018
(0.4724-0.4731)
11.966-11.984
(0.4711-0.4718)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure 1 300-I 600 kPa 1100 kPa
STANDARD
LIMIT
0.10
(0.004)
128.9
(5.07)
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
t 13-16 185-228 kg/cm2 j
Compression pressure
difference
Piston to cylinder clearance 0.045-0.055 0.120
(0.0018-0.0022)
Cylinder bore 83.000-83.015 83.085
(3.2677-3.2683)
Piston diam. 82.950-82.965
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion 0.05
Piston ring free end gap
Piston ring end gap
Piston ring clearance groove
1st R
2nd R
1 st
2nd 0.20-0.35 0.70
1 st
2nd 0.150
(3.2657-3.2663) 82.880
psi
Approx. $.:153,
Approx. &>i5r
0.20-0.35 0.70
(0.008-0.014) (0.028)
(0.008-0.014)~ (0.028)
i 1 1 156 kg/cm* i
200 kPa
2 kg/cm2
!
28 psi 1
(0.0047)
(3.271 1)
(3.2630)
(0.002)
CO%,
co93for
0.180
(0.007)
(0.006)
psi
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