Suzuki VX800 1990-1993 Service Manual 08 Chassis

~~~~~ ~~ ~~~~~~ CONTENTS ~~

FRONT WHEEL

REMOVAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING

FRONT BRAKE

BRAKE PAD REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 5

CALIPER REMOVAL AND DISASSEMBLY .......+..........8- 6

CALIPER AND DISC INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 6

CALIPER REASSEMBLY AND REMOUNTING . . . . . . . . . . . . . . .8_ 7

MASTER CYLINDER REMOVAL AND DISASSEMBLY . ..8- 8 MASTER CYLINDER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 8

MASTER CYLINDER REASSEMBLY AND REMOUNTING

FRONT FORK

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8s 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 10

DlSASSEMBL Y.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 11

INSPECTION REASSEMBLY AND REMOUNTING

STEERING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 75

REMOVAL DISASSEMBL Y

IN_CPFf?TlflN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . & 16

.m .V,

---m-m.

REASSEMBLY AND REMOUNTING STEERING TENSION ADJUSTMENT IGNITION SWITCH

REAR BRAKE

BRAKE PAD REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 12

. . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_ I6

. . . . . . . . . . . . . . . . . . . . . . . . . . .8_ 16

. . . . . . . . . . . . . . . . . . . . . . . . . . . 8_ 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_20

CALIPER REMOVAL AND DISASSEMBL Y . . . . ’ ’ . . . . . . . . . . . . B-2 1

CALIPER AND DISC INSPECTION

n 1 I ,m#-m mr 1 mmr.*m* ,I 1 .I_ mr..m. I.ITI..fi

CIHLlrKfl KtH33LIIVlCIL T UIVLJ

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_22

HtMLJUlV

I INU . . . . ’ . . . . . . . . . ’ 8-22

MASTER CYLINDER REMOVAL AND DISASSEMBLY . ..8-23 MASTER CYLINDER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_24

MASTER CYLINDER REASSEMBLY AND REMOUNTING

REAR WHEEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_26

REMOVAL AND DlSASSEMBL Y.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_26

INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING

TIRE AND WHEEL

TIRE REMOVAL

INSPECTION

TIRE MOUNTING

RFA R _Cl I_CPFN_ClfIN A N/3 S WING

, .__, . VI_, I,._,_,. _..I _.I mn.-s .m .m.m

REMOVAL INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_34

ARM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_38

REASSEMBLY AND REMOUNTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_28

. . . . . . . . . . . . . . . . . . . . . . . . . . .8_29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .&36

. . . . . . . . . . . . . . . . . . . . . . . . . . .8_38

FINAL INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . .8-39

REASSEMBLY INFORMATION

SUSPENSION SETTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_4I

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8_40

FRONT WHEEL

Th1360 : Apply THREAD LOCK SUPER “1360.”

Tightening torque

1. Support

2. Loosen the axle pinch bolt.

09900-00410 : Hexagon wrench set

3. Remove the axle shaft and the front wheel.

09900-l 8710 : 12 mm hexagon socket

CAUTION:

Do not operate the brake lever while dismounting the front

wheel.

the

motorcycle with

the center stand and a jack.

G : Apply SUPER GREASE “A.”

CHASSIS 8-2

INSPECTION AND

DISASSEMBLY

SPEEDOMETER GEAR BOX DUST SEAL

Inspect the lip of dust seal for damage.

TIRE

Refer to page 8-31.

WHEEL BEARINGS

Inspect the play of the wheel bearings by hand whiie they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual.

To remove the wheel bearings, use the

snecial tog! in the

-r--.-’

following procedures:

09941-50110 : Bearing remover

Plan

Play

Insert the adaptor into the wheel bearing.

‘)\ II**-.. :,..-,+:,, +l-... . ..^ rl,.-. L.I” SC_, +L, P.,..,,;+, .-.:A,

L, H,K, 111se, LllllJ Lilt: ““a”ye “cl,

II”,,, LI,e: “cJIJ”S1K 31ve, 1”C.R

l--l,

the wedge bar in the slit of the adaptor.

3) Drive out the wheel bearing by knocking the wedge bar.

CAUTION:

The removed bearings should be replaced with new ones.

Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.

09900-20606 :

Dial gauge (l/100) 09900-20701 : Magnetic stand 09900-21304 : V-block set (100 mm)

Service limit : 0.25 mm (0.010 in)

WHEEL

Make sure that

the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosen wheel bearings. If bearing replacement fails to

reduce the runout, replace the wheel.

Service limit (Axial and Radial) : 2.0 mm

(0.08

in)

8-3 CHASSIS

REASSEMBLY AND REMOUNTING

Reassemble and remount the front wheel in the reverse order of removal and disassembly. Pay attention to the following points:

WHEEL BEARING

Apply grease to the bearing before installing.

---‘-_

(For U.S.A. model) 99000-25030 : SUZUKI SUPER GREASE “A”

(For the other models) 99000-25010 : SUZUKI SUPER GREASE “A”

Install the wheel bearings as follows by using the special

tool.

09924-84510

Bearing installer set

NOTE:

First instaii the ieft wheei bearing, then instaii the right wheei bearing. The sealed cover on the bearing is positioned outside.

Left +

I Right

Left +

4 Right

Bearing installer

BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter. Apply THREAD LOCK SUPER “1360” to the disc mounting bolts and tighten them to the specified torque.

99000-32130 : THREAD LOCK SUPER “1360”

Tightening torque : 18 - 28 N-m

(1.8 - 2.8 kg-m, 13.0 - 20.0 lb-ft)

Spacer

SPEEDOMETER GEARBOX

Before installing the speedometer gearbox, apply grease to its dust seal lip.

(For U.S.A. model)

99000-25030 : SUZUKI SUPER GREASE “A”

(For the other models)

99000-25010 : SUZUK

SUPER GREASE “A”

CHASSIS 84

Fit two drive lugs @

into recesses @ of the wheel hub.

Set the stopper on the speedometer gearbox to lug on the left front fork. When tightening the front axle, make sure that the speedometer gearbox is in position and the speedometer cable does not bend sharply.

AXLE SHAFT

Tighten the axle shaft to the specified torque.

Tightening torque : 36 - 52 N-m

(3.6 - 5.2 kg-m, 26.0 - 37.5 lb-ft)

Tighten the axle pinch bolt to the specified torque.

Tightening torque : 18 - 28 N.m

(1.8

- 2.8 kg-m, 13.0 - 20.0 lb-ft)

8-5 CHASSIS

FRONT BRAKE

SG : Apply SILICONE GREASE.

BRAKE PAD REPLACEMENT

Remove the brake caliper by removing the mounting bolts.

09900-00410 : Hexagon wrench set

2. Remove the pads.

CAUTION:

* Do not operate the brake lever while dismounting the pads.

* Replace the brake pads as a set, otherwise braking perfor-

mance will be adversely affected.

CALIPER REMOVAL AND DISASSEMBLY

1. Disconnect the brake hose from the caliper by removing the union bolt and catch the brake fluid in a suitable receptacle.

CAUTION:

Never reuse the

for long periods.

WARNING: Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joint for cracks and oil leakage.

Remove the caliper mounting bolts and take off the caliper.

3. Remove the pads.

brake

iiuid

ieft over from servicing and stored

CHASSIS 8-6

4. Place a rag over the pistons to prevent them from popping out and push out the pistons by using the air gun.

CAUTION: Do not use high pressure air to prevent piston damage.

Remove the pistons 0, dust seals @ and piston seals @ out

of the caliper.

CALIPER AND DISC INSPECTION

CALIPER

Inspect the caliper bore wall for nicks, scratches or other

damage.

PISTON

Inspect the piston surface for any scratches or other damage.

8-7 CHASSIS

DISC

Using a micrometer, check the disc for wear, its thickness can be checked with disc and wheel in place. The service limits for the thickness of the discs are shown below.

09900-20205 : Micrometer (0 - 25 mm)

Service limit (Front) : 5.0 mm (0.20 in)

(Rear)

With the disc mounted on the wheel, check the disc for face

runout with a dial gauge, as shown.

09900-20606 : Dial gauge (l/100 mm) 09900-20701 : Magnetic stand

Service limit : 0.30 mm (0.012 in)

5.5 mm (0.22 in)

CALIPER REASSEMBLY

Reassemble the caliper in the reverse order of removal and disassembly. Pay attention to the following points:

CAUTION

Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.

* Apply brake fluid to the caliper bore and piston to be

inserted into the bore.

CALIPER BOLTS

Tighten each bolt to the specified torque.

Tightening torque

Front brake caliper

mounting bolt @ : 30 - 48 N-m

Brake hose union bolt @

CAUTION: Bleed air after reassembling the caliper. (Refer to page 2-13).

(3.0 - 4.8 kg-m, 21.5 - 34.5 lb-ft)

15 - 20 N.m (1.5 - 2.0 kg-m, 11.0 - 14.5 lb-ft)

AND REMOUNTING

NOTE: Before remounting the caliper, push the piston all the way into the caliper.

MASTER CYLINDER REMOVAL AND DISASSEMBLY

Remove the

Place

a rag underneath the union bolt on the master cylinder

to catch the spilled drops of brake fluid. Remove the union

bolt and disconnect the brake hose/master cylinder joint.

CAUTION: Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics and rubber materials, etc. and will damage them severely.

3. Remove the master cylinder assembly.

Remove the front brake lever, reservoir cap and diaphragm.

5. Drain brake fluid.

front brake light switch lead wires.

CHASSIS 8-8

Remove the dust seal, then remove the circlip by using the

special tool.

09900-06108 :

Remove the piston/secondary cup, primary cup and spring.

Snap ring pliers

@ Secondary cup @ Piston 0 Primary cap @ Return spring

MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or other

damage.

Inspect the piston surface for any scratches or other damage.

Inspect the primary cup, secondary cup and dust seal for

wear or damage.

8-9 CHASSIS

MASTER CYLINDER REASSEMBLY AND REMOUNTING

Reassemble the master cylinder in the reverse order of removal

and disassembly. Pay attention to the following points:

CAUTION:

Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all the component to be inserted into the bore.

When remounting the master cylinder on the handlebar, align the master cylinder holder’s mating surface @ with punched mark @ on the handlebar and tighten the upper clamp bolt first as shown.

Tightening torque : 5 - 8 N-m

(0.5 - 0.8 kg-m, 3.5 -

6.0

lb-It)

CAUTION: Bleed air after reassembling master cylinder. (Refer to page 2-13).

Master cylinder

Upper clamp

bolt

Clearance

FRONT FORK

CHASSIS 8-l 0

Th1342 : Apply THREAD LOCK “1342.”

Tightening torque

REMOVAL

1. Support the motorcycle with the center stand and a jack.

2. Remove the front wheel. (Refer to page 8-l.)

3. Remove the brake caliper.

09900-00401

CAUTION: Hang the brake caliper from the motorcycle frame by using a string, etc., taking care not to bend the brake hose.

4. Disconnect the speedometer cable from the speedometer and remove the front fender.

5. Remove the fender brace.

L” type hexagon wrench set

: ”

G : Apply SUPER GREASE “A.”

Item N.m

15-30 1.5-3.0 11.0-21.5 18 -28 1.8-2.8 13.0-20.0 25 - 35 2.5 - 3.5 18.0 - 25.5

kg-m

lb-ft

8-11 CHASSIS

NOTE:

Slightly loosen the front fork cap bolts @ to facilitate later

disassembly before loosening the front fork clamp bolts.

6. Loosen the front fork upper and lower clamp bolts.

7. Remove the front forks.

DISASSEMBLY

1. Remove the front fork cap bolt.

2. Remove the spacer, spring seat and spring out of the inner

tube.

3. Turn the fork upside down and stroke it several times to let out fork oil.

4. Hold the fork upside down for a few minutes to drain oil.

5. While holding the caliper mounting portion @ by vise and remove the damper rod with the special tool and the hexagon wrench.

09900-0040 1 : “L” type hexagon wrench set 09940-34520 : T-handle 09940-34592 : Attachment “G”

6. Remove the dust seal and the oil seal stopper ring.

7. Pull the inner tube out of the outer tube.

CAUTION:

The outer tube and inner tube “anti-friction” metals must be replaced along with the oil seal and dust seal.

8. Remove the damper rod and the rebound spring out of the inner tube.

@ Dust seal @I Oil seal stopper ring 0 Oil seal 0 Oil seal retainer @ Anti-friction metal (Outer tube metal) 6? Anti-friction metal (Inner tube metal)

INSPECTION

DAMPER ROD RING Inspect the damper rod ring for wear or damage.

INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding

surface for any scuffing.

CHASSIS 8-12

FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.

Service limit

For E-01,03,28,33 models For the other models

353 mm (13.9 in) 348 mm (13.7 in)

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points:

INNER TUBE METAL

Hold the inner tube vertically and clean the metal groove

and install the metal by hand as shown.

CAUTION: Use special care to prevent damage to the “Teflon” coated

surface of the “anti-friction” metal when mounting it.

DAMPER ROD BOLT

Replace the gasket with a new one. Apply THREAD LOCK

“1342” to the damper rod bolt and tighten it to the speci-

fied torque.

Replace

99000-32050 : THREAD LOCK “1342”

Tightening torque : 25 - 35 N-m

(2.5 - 3.5 kg-m, 18.0 - 25.5 lb-ft)

OUTER TUBE METAL, OIL SEAL AND DUST SEAL

Clean the metal groove of outer tube and metal outer surface.

Install the outer tube metal, oil seal retainer and oil seal.

09949-59113

CAUTION: Use special care to prevent damage to the “Teflon” coated

surface of the “anti-friction” metal when installing it.

Front fork oil seal installer

THREAD LOCK “1342”

+ 29 hidden pages