Suzuki Marauder VZ800 - Workshop Manual / Repair Manual

SUZUKI VZ800 - WORKSHOP, SERVICE, REPAIR MANUAL

- English Workshop Manual, to Suzuki Marauder VZ800.

 

INDEX:


FOREWORD
HOW TO USE THIS MANUAL
- To locate what you are looking for
- Component parts and work to be done
- Symbol
- Abbreviations used in this manual
- Sae-to-former suzuki term
- Wire color
01 GENERAL INFORMATION
- Warning/caution/note
- General precautions
- Suzuki vz800k5 (’05-model)
- Serial number location
- Fuel, oil and engine coolant recommendation
- Fuel (for usa and canada)
- Fuel (for other countries)
- Engine oil
- Brake fluid
- Front fork oil
- Engine coolant
- Water for mixing
- Anti-freeze/engine coolant
- Liquid amount of water/engine coolant
- Break-in procedures

- Cylinder identification
- Information labels
- Specifications
02 PERIODIC MAINTENANCE
- Periodic maintenance schedule
- Periodic maintenance chart
- Lubrication points
- Maintenance and tune-up procedures
- Air cleaner
- Spark plug
- Valve clearance
- Fuel hose
- Engine oil and oil filter
- Engine idle speed
- Throttle cable play
- Throttle valve synchronization
- Evaporative emisson control sys-tem (for e-33 only)
- Pair (air supply) system
- Clutch
- Cooling system
- Final gear oil
- Brake
- Tire
- Steering
- Front fork
- Rear suspension
- Exhaust pipe bolt
- Chassis bolt and nut
- Compression pressure check
- Compression test procedure
- Oil pressure check
- Oil pressure test procedure
- Sds check
- Sample:
- Data sampled from cold starting through warm-up
- Data at 3000 r/min under no load
- Data at the time of racing
03 ENGINE
- Engine components removable with engine in place
- Engine removal and installation
- Engine removal
- Engine installation
- Engine disassembly
- Engine components inspection and servicing
- Cylinder head cover
- Camshaft
- Cam chain tensioner and guide
- Cylinder head
- Cylinder
- Piston
- Conrod/crankshaft
- Clutch
- Generator/signal generator/ starter clutch
- Oil pump
- Transmission
- Gearshift fork
- Oil jet
- Crankcase
- Engine reassembly
04 SHAFT DRIVE
- Secondary bevel gears
- Construction
- Removal
- Disassembly
- Inspection
- Secondary gear shims adjustment
- Reassembly
- Installation
- Final bevel gears
- Construction
- Final gear case removal
- Final gear case disassembly
- Final gear shims adjustment
- Final gear case reassembly
- Final gear case installation
05 FI SYSTEM
- Precautions in servicing
- Connector/coupler
- Fuse
- Ecm/various sensors
- Electrical circuit inspection procedure
- Using the multi-circuit tester
- Fi system technical features
- Injection time (injection volume)
- Compensation of injection time (volume)
- Injection stop control
- Fi system parts location
- Fi system wiring diagram
- Ecm terminal
- Self-diagnosis function
- User mode
- Dealer mode
- Tps adjustment
- Fail-safe function
- Fi system troubleshooting
- Customer complaint analysis
- Visual inspection
- Self-diagnostic procedures
- Self-diagnosis reset procedure
- Use of sds diagnostic procedures
- Use of sds diagnosis reset proce-dure
- Show data when trouble (displaying data at the time of dtc)
- Malfunction code and defective condition
- “c12” (p0335) ckp sensor circuit malfunction
- “c13” (p1750) or “c17” (p0105) iap sensor circuit malfunction
- “c14” (p0120-h/l) tp sensor circuit malfunction
- “c15” (p0115-h/l) ect sensor circuit malfunction
- Ect sensor inspection
- “c21” (p0110-h/l) iat sensor circuit malfunction
- “c23” (p1651-h/l) to sensor circuit malfunction
- “c24” (p0351) or “c25” (p0352) ignition system malfunction
- “c28” (p1655) stv actuator circuit malfunction
- “c29” (p1654-h/l) stp sensor circuit malfunction
- “c31” (p0705) gp switch circuit malfunction
- “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction
- “c41” (p0230) fp relay circuit malfunction
- “c42” (p01650) ig switch circuit malfunction
- “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24)
- “c49” (p1656) pair control solenoid valve circuit malfunction
- Sensors
- Iap sensor inspection
- Iap sensor removal/installation
- Tp sensor inspection
- Tp sensor removal/installation
- Stp sensor inspection
- Stp sensor removal/installation
- Ckp sensor inspection
- Ckp sensor removal/installation
- Iat sensor inspection
- Iat sensor removal/installation
- Ect sensor inspection
- Ect sensor removal/installation
- To sensor inspection
- To sensor removal/installation
- Ho2 sensor inspection (for e-02, 19, 24)
- Ho2 sensor removal/installation
06 FUEL SYSTEM AND THROTLE BODY
- Fuel delivery system
- Fuel system
- Fuel tank removal
- Fuel tank installation
- Fuel pressure inspection
- Fuel pump inspection
- Fuel discharge amount inspection
- Fuel pump relay inspection
- Fuel pump removal and disassembly
- Fuel mesh filter inspection and cleaning
- Fuel pump reassembly and installa-tion
- Throttle body
- Construction
- Air cleaner box removal
- Air cleaner box installation
- Throttle body removal
- Throttle body disassembly
- Throttle body cleaning
- Inspection
- Throttle body reassembly
- Throttle body installation
- Stp sensor adjustment
- Fuel injector removal
- Fuel injector inspection
- Fuel injector installation
- Fast idle
- Fast idle adjustment
- Throttle valve synchronization
- Throttle position sensor (tps) setting
07 COOLING AND LUBRICATION SYSTEM
- Engine coolant
- Cooling circuit
- Cooling circuit inspection
- Radiator and water hoses
- Radiator removal
- Radiator cap inspection
- Radiator inspection and cleaning
- Radiator remounting
- Water hose and reservoir tank inspection
- Cooling fan
- Inspection
- Removal
- Installation
- Cooling fan thermo-switch
- Removal
- Inspection
- Installation
- Engine coolant temperature sensor
- Removal
- Inspection
- Installation
- Thermostat
- Removal
- Inspection
- Installation
- Water pump
- Removal and disassembly
- Inspection
- Reassembly and installation
- Lubrication system
- Oil pressure
- Oil filter
- Oil pressure regulator
- Oil strainer
- Oil jet
- Oil pump
- Oil pressure switch
- Engine lubrication system chart
08 CHASSIS
- Exterior parts
- Removal
- Remounting
- Front wheel
- Construction
- Removal and disassembly
- Inspection
- Reassembly and remounting
- Front fork
- Construction
- Removal and disassembly
- Inspection
- Reassembly and remounting
- Handlebar
- Construction
- Removal and disassembly
- Reassembly and remounting
- Steering
- Construction
- Removal and disassembly
- Inspection and disassembly
- Reassembly and remounting
- Steering tension adjustment
- Rear wheel
- Construction
- Removal
- Disassembly
- Inspection and disassembly
- Reassembly and remounting
- Rear suspension
- Construction
- Removal
- Inspection and disassembly
- Reassembly
- Remounting
- Rear shock absorber disposal
- Suspension setting
- Front brake
- Construction
- Brake pad replacement
- Brake fluid replacement
- Brake caliper removal and disassembly
- Brake caliper inspection
- Brake caliper reassembly and remounting
- Brake disc inspection
- Master cylinder removal and disassembly
- Master cylinder inspection
- Master cylinder reassembly and remounting
- Rear brake
- Construction
- Removal and disassembly
- Inspection
- Reassembly and remounting
- Rear brake rod
- Reassembly remounting
- Tire and wheel
- Tire removal
- Inspection
- Valve inspection
- Tire installation
- Balancer weight installation
09 ELECTRICAL SYSTEM
- Cautions in servicing
- Connector
- Coupler
- Clamp
- Fuse
- Semi-conductor equipped part
- Battery
- Connecting the battery
- Wiring procedure
- Using the multi-circuit tester
- Location of electrical components
- Charging system
- Troubleshooting
- Inspection
- Starter system and side-stand/ignition interlock system
- Troubleshooting
- Starter motor removal and disassembly
- Starter motor inspection
- Starter motor reassembly
- Starter relay inspection
- Side stand/ignition interlock system parts inspection
- Ignition system
- Troubleshooting
- Inspection
- Speedometer and pilot lamp box
- Description
- Speedometer removal and disassembly
- Pilot lamp box removal and disassembly
- Inspection
- Lamps
- Headlight, brake light/taillight, license plate light and turn signal light
- Relays
- Turn signal/side-stand relay
- Starter relay
- Fuel pump relay
- Switches
- Battery
- Specifications
- Initial charging
- Servicing
- Recharging operation
10 SERVICING INFORMATION
- Troubleshooting
- Fi system malfunction code and defective condition
- Engine
- Radiator (cooling system)
- Chassis
- Shaft drive
- Brakes
- Electrical
- Battery
- Wiring harness, cable and hose routing
- Wiring harness routing
- Cable routing
- Throttle body installation
- Cooling system hose routing
- Front brake routing
- Speed sensor harness routing
- Front turn signal installation
- Front turn signal lead wire routing
- Muffler & exhaust pipe installation
- Handlebar balancer
- Battery protector
- Lubrication points
- Fuel tank installation
- Rear combination lamp installation
- Frame head cover cushion installation
- Left side cover cushion installation
- Rear fender cushion installation
- Left side cover installation
- Lid cushion instsallation
- Tail lamp installation
- Pair (air supply) system diagram
- Pair (air supply) system hose routing
- Special tools
- Tightening torque
- Engine
- Secondary and final
- Fi system and intake air system
- Cooling system
- Chassis
- Tightening torque chart
- Service data
11 EMISSION CONTROL INFORMATION
- Emission control systems
- Fuel injection system
- Exhaust emission control system (pair system)
- Noise emission control system
- Evaporative emission control system (only for e-33)
- Pair (air supply) system inspection
- Hoses
- Pair reed valve
- Pair control solenoid valve
- Pair (air supply) system hose routing
- Heated oxgen sensor (ho2s) inspection (for e-02, 19, 24)
- Evaporative emission control system inspection (only for e-33)
- Hoses (evap hose)
- Evap canister
- Evap canister hose routing (only for e-33)
12 VZ800K6 ('06 MODEL)
- Specifications
- Service data
- Exhaust emission control system (pair system)
13 VZ800K7 ('07 MODEL) & VZ800K8 ('08 MODEL)
- Specifications
- Service data
- Fuel pump and fuel level gauge removal
- Fuel pump and fuel level gauge installation
- Speedmeter and pilot lamp box inspection
- Fuel level meter inspection
- Fuel level gauge inspection
- Switches
- Front brake hose routing
- Wiring harness cable routing
14 VZ800K9 (’09-MODEL)
- Abbreviations used in this manual
- Sae-to-former suzuki term
- Country and area codes
- Specifications
- Periodic maintenance schedule
- Periodic maintenance chart
- Maintenance and tune-up procedures
- Air cleaner
- Spark plug
- Valve clearance
- Engine oil and oil filter
- Throttle cable play
- Throttle valve synchronization
- Evaporative emisson control system (e-33 only)
- Fi system diagnosis
- Fi system wiring diagram
- Ecm terminal
- Fail-safe function
- Dtc table and defective condition
- Dtc troubleshooting
- Throttle body
- Construction
- Throttle body removal
- Throttle body disassembly
- Throttle body cleaning
- Throttle body inspection
- Throttle body reassembly
- Throttle body installation
- Stp sensor adjustment
- Tp sensor adjustment
- Isc valve removal
- Isc valve installation
- Isc valve inspection
- Isc valve preset and opening initialization
- Throttle valve synchronization
- Ignition system
- Inspection
- Wiring harness routing
- Cable routing
- Speed sensor harness routing
- Throttle body installation
- Ignition coil installation
- Engine mounting
- Muffler & exhaust pipe installation
- Pair (air supply) system hose routing
- Special tools
- Tightening torque
- Engine
- Service data
- Emission control system
- Exhaust emission control system (pair system)
- Evaporative emission control system (only for e-33)
- Pair (air supply) system inspection
- Heated oxygen sensor (ho2s) inspection(for e-02, 19, 24, 33)
- Evaporative emission control system inspection(only for e-33)
- Evap system purge control solenoid valve
- Fuel shut-off valve
- Pair (air supply) system diagram
- Pair (air supply) system hose routing
- Evap canister hose routing (only for e-33)
15 WIRING DIAGRAM