GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
SHAFT DRIVE
4
FI SYSTEM
5
FUEL SYSTEM AND THROTTLE
BODY
6
COOLING AND LUBRICATION
SYSTEM
7
CHASSIS
8
ELECTRICAL SYSTEM
9
SERVICING INFORMATION
10
EMISSION CONTROL
INFORMATION
11
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
FOREWORD
This manual contains an introductory description on
the SUZUKI VZ800 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
99500-3805 4-03E
SUPPLEMENTS
VZ800K6 ('06-MODEL)
VZ800K7&K8 ('07&'08-MODELS)
VZ800K9 ('09-MODEL)
12
13
14
WIRING DIAGRAM
15
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1 Front axle 6 Brake disc
2 Bearing (R) 7 Spacer
3 Front wheel ITEM N·m kgf-m lb-ft
4 Spacer A Front axle A 65 6.5 47.0
5 Bearing (L) B Brake disc mounting bolt B 23 2.3 16.5
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply oil. Use engine oil unless other-
wise specified.
Use engine coolant.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Use fork oil.
99000-99044-L01
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in resistance range.
Apply SUZUKI BOND “1207B”.
99000-31140
Measure in current range.
Apply SUZUKI BOND “1216B”.
99000-31230
Measure in diode test range.
Apply THREAD LOCK SUPER “1303”.
99000-32030
Measure in continuity test range.
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
Use special tool.
Apply THREAD LOCK “1342”.
99000-32050
Indication of service data.
1216
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Suzuki VZ800 Marauder Boulevard M50 Service Repair Manual 2005-2009
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Full Search Facility
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Description
This is a comprehensive repair and service manual for the 2005-2009 Suzuki VZ800 Marauder Boulevard M50. It is a valuable resource for both professional mechanics and DIY enthusiasts.
- General Information
- Specifications
- Maintenance
- Gearbox & Clutch
- Engine Removal and Installation
- Engine Fuel System
- Engine Lubrication and Cooling
- Engine Combustion System
- Lubrication System
- Cylinder Head/Valves
- Alternator/Starter Clutch
- Crankcase/Piston/Cylinder
- Crankshaft/Transmission/Balancer
- Transmission System
- Front Wheel and Steering System
- Rear Wheel System
- Fenders and Exhaust Pipe
- Periodic checks & Adjustments
- Chassis
- Cooling system
- Fuel injection system
- Braking System
- Suspension
- Electrical System
- Body & Fixtures
- Frame/Body Panels/Exhaust System
- Wheels & Tyres
- Battery/Charging System
- Ignition System
- Electric Starter
- Lights/Meters/Switches
- Wiring Diagrams
- Technical Information & Specifications
- Troubleshooting
This manual is available in English and is compatible with all versions of Windows and Mac. It requires Adobe Reader for access.
The manual provides detailed instructions, illustrations, diagrams, specifications, and procedures for repair, maintenance, rebuilding, refurbishing, and restoration of the vehicle.
With printable pages, it offers convenience for use at home, in the office, or at the repair shop. By following the step-by-step instructions, individuals of any skill level can save money by performing their own repairs.
Instant access eliminates shipping costs and waiting time for delivery. Upon payment completion through our secure processor, you will receive the manual immediately. We accept all major credit/debit cards and PayPal.
