Suzuki Intruder VS700, Service Manual

Page 1: ...VS700 750 800 Service Manual 99500 38062 03E 9 9 5 0 0 3 8 0 6 3 0 3 E ...

Page 2: ...udes specific information required to properly inspect and service this street legal motorcycle in accordance with all EPA regulations It is strongly recommended that the chapter on Emission Control Periodic Servicing and FI System and Fuel System be thoroughly reviewed before any type of service work is performed Further information concerning the EPA emission regulations and U S Suzuki s emissio...

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Page 5: ...AL INFORMATION PERIODIC MAINTENANCE AND TUNE UP PROCEDURES ENGINE SHAFT DRIVE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM 1 2 3 4 5 6 7 CHASSIS SERVICING INFORMATION 8 9 10 EMISSION CONTROL INFORMATIONS ...

Page 6: ...750GLFM GLPM 91 MODEL 11 12 13 14 15 VS800GLN 92 MODEL VS800GLP R 93 94 MODEL VS800GLS 95 MODEL VS800GLT V 96 97 MODEL 16 17 18 19 VS800GLW X 98 99 MODEL VS800GLY K1 K2 K3 00 01 02 03 MODEL 20 21 VS800GLK4 04 MODEL VS800K5 05 MODEL VS800K6 06 MODEL VS800K7 07 MODEL 22 SUPPLEMENTS 26 VS800K8 08 MODEL ...

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Page 273: ...11 VS700GLE ...

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Page 294: ...VS700GLH 87 MODEL 12 ...

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Page 318: ...VS750GLJ 88 MODEL 13 ...

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Page 344: ...VS750GLK 89 MODEL 14 ...

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Page 363: ...VS800GLN 92 MODEL 16 ...

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Page 394: ...VS800GLP R 93 94 MODEL 17 ...

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Page 406: ...VS800GLS 95 MODEL 18 ...

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Page 422: ...VS800GLT V 96 97 MODEL 19 ...

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Page 443: ...VS800GLW X 98 99 MODEL 20 ...

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Page 456: ...of the VS800GLX 99 MODEL CONTENTS SPECIFICATIONS 21 1 SERVICE DATA 21 2 STEERING STEM 21 13 CABLE ROUTING 21 14 Y MODEL E 02 03 04 17 18 22 25 28 33 34 37 P 22 37 K1 MODEL E 03 17 22 25 28 33 34 K2 MODEL E 03 17 22 25 28 33 34 K3 MODEL E 03 17 22 25 28 33 VS800GLY K1 K2 K3 00 01 02 03 MODEL ...

Page 457: ...reload 5 way adjustable Front fork stroke 130 mm 5 1 in Rear wheel travel 90 mm 3 5 in Caster 32 40 Trail 138 mm 5 43 in Steering angle 40 right left Turning radius 2 9 m 9 5 ft Front brake Disk brake Rear brake Drum brake Front tire size 100 90 19 57H tube type Rear tire size 140 90 15 M C 70H tube type ELECTRICAL Ignition type Electronic ignition Transistorized Ignition timing 5 B T D C at 1 200...

Page 458: ... O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 4 0 0 16 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length INNER 38 3 1 51 OUTER 40 1 1 58 Valve spring tension INNER 6 51 7 49 kg 14 35 16 51 lbs at length 32 5 mm 1 28 in OUTER...

Page 459: ...tortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 300 1 600 kPa 1 100 kPa 13 16 kg cm2 11 kg cm2 185 228 psi 156 psi Compression pressure difference 200 kPa 2 kg cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 120 0 0018 0 0022 0 0047 Cylinder bore 83 000 83 015 83 085 3 2677 3 2683 3 2711 Piston dia...

Page 460: ...g end side clearance 0 10 0 20 0 30 0 004 0 008 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 080 0 0009 0 0017 0 0031 Crank pin O D 40 982 41 000 1 6135 1 6142 Crankshaft journal oil clearance 0 020 0 050 0 080 0 0008 0 0020 0 0031 Crankshaft journal O D 47 965 47 980 1 8884 1 8890 Crankshaft thrust bearing 1 ...

Page 461: ...lease cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston 38 042 38 075 diam 1 4977 1 4990 TRANSMISSION Unit mm in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 133 30 30 17 15 Final reduction ratio 3 090 34 11 Gear ratios Low 2 285 32 14 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0 851 23 27 Shift fork to groove clea...

Page 462: ...4 in Main jet M J 107 5 95 Jet needle J N 5F109 3rd 5C29 3rd Needle jet N J P 3 P 4 Throttle valve Th V 115 Pilot jet P J 42 5 40 Pilot screw P S PRE SET 1 turns back PRE SET 1 turns back Throttle cable play 2 4 mm 0 08 0 16 in CARBURETOR ITEM SPECIFICATION E 03 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E1 Idle r min 1 200 50 r min Float height 27 7 1 0 mm 9 1...

Page 463: ...Pilot jet P J 42 5 40 Pilot screw P S PRE SET 1 turns back PRE SET 1 turns back Throttle cable play 2 4 mm 0 08 0 16 in CARBURETOR ITEM SPECIFICATION E 17 22 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38EA Idle r min 1 100 100 r min Float height 27 7 1 0 mm 9 1 1 0 mm 1 09 0 04 in 0 36 0 04 in Main jet M J 107 5 100 Jet needle J N 5F109 3rd 5C29 3rd Needle jet N ...

Page 464: ...2 Throttle valve Th V 125 110 Pilot jet P J 45 40 Pilot screw P S PRE SET 1 turns back PRE SET 1 turns back Throttle cable play 2 4 mm 0 08 0 16 in CARBURETOR ITEM SPECIFICATION E 33 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E5 Idle r min 1 200 50 r min Float height 27 7 1 0 mm 9 1 1 0 mm 1 09 0 04 in 0 36 0 04 in Main jet M J Jet needle J N 5D35 1st 5D47 1st ...

Page 465: ...ming 5 B T D C at 1 200 r min Firing order 1 2 Spark plug Type N G K DPR8EA 9 ND X24EPR U9 Gap 0 8 0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm Signal coil resistance Approx 50 200 Ω G Bl Ignition coil resistance Primary 2 6 Ω tap tap Secondary 15 40 kΩ Plug cap tap Generator no load voltage More than 75V AC at 5 000 r min When engine cold Generator Max output 250 W at 5 000 r min Regulat...

Page 466: ...TEM STANDARD LIMIT Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 40 1 6 Brake lining thickness Rear 1 5 0 056 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 5 0 0 2 4 5 0 20 0 01 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4993 Brake caliper cylinder bore Front 42 8...

Page 467: ...ION Unit mm in ITEM STANDARD LIMIT NOTE Front fork stroke 130 5 12 Front fork spring free length 348 3 13 71 Front fork oil level 124 3 4 89 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 30 0 012 TIRE PRESSURE NORMAL RIDING COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kg cm2 psi kPa kg cm2 psi FRONT 200 2 00 29 225 2 25 33 REAR 225 2 25 33 250 2 50 36 ...

Page 468: ...nal bevel gear oil capacity 200 220 ml 6 8 7 0 7 4 7 7 US lmp oz Brake fluid type DOT 4 Coolant capacity 1 700 ml 1 8 1 5 US lmp qt THERMOSTAT RADIATOR FAN ITEM STANDARD LIMIT Thermostat valve opening temperature 75 0 1 5 C 167 2 7 F Thermostat valve lift Over 6 mm 0 24 in at 90 C 194 F Radiator cap valve release 1 1 0 15 kg cm2 pressure 15 6 2 1 psi 110 15 kPa Electric fan thermo ON Approx 105 C ...

Page 469: ...type X 99 MODEL Y 2000 MODEL 1 Handlebar upper holder 2 Handlebar lower holder 3 Handle stay 4 Bush 5 Steering stem head 6 Bush 7 Washer 8 Washer 9 Steering stem nut 0 Dust seal A Steering stem upper bearing B Steering stem C Steering stem lower bearing A Handlebar clamp bolt B Handlebar holder mounting bolt C Handlebar holder nut D Steering stem head nut E Front fork lower clamp bolt Tightening t...

Page 470: ...VS800GLY K1 K2 K3 00 01 02 03 MODEL 21 14 CABLE ROUTING Clamp Wiring harness Wiring harness ...

Page 471: ...scribes service data service specifications and servicing procedures which differ from those of the VS800GLK3 03 MODEL NOTE Please refer to the chapter 1 through 21 for details which are not given in this chapter SPECIFICATIONS 22 2 SERVICE DATA 22 3 WIRING DIAGRAM 22 12 ...

Page 472: ...roke 130 mm 5 1 in Rear wheel travel 90 mm 3 5 in Caster 32 40 Trail 138 mm 5 43 in Steering angle 40 right left Turning radius 2 9 m 9 5 ft Front brake Disk brake Rear brake Drum brake Front tire size 100 90 19 M C 57H tube type or 100 90 19 57H tube type Rear tire size 140 90 15 M C 70H tube type or 140 90 15 70H tube type ELECTRICAL Ignition type Electronic ignition Transistorized Ignition timi...

Page 473: ... 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem and length IN EX 4 0 0 16 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length INNER 38 3 1 51 OUTER 40 1 1 58 Valve spring tension INNER 6 51 7 49 kg 14 35 16 51 lbs at len...

Page 474: ...711 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 300 1 600 kPa 13 16 kgf cm2 185 228 psi 1 100 kPa 11 kgf cm2 156 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 Cylinder bore 83 000 83 015 3 2677 3 2683 83 085 3 2711 Piston diam 82 950...

Page 475: ...g end side clearance 0 10 0 20 0 004 0 008 0 30 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 0009 0 0017 0 080 0 0031 Crank pin O D 40 982 41 000 1 6135 1 6142 Crankshaft journal oil clearance 0 020 0 050 0 0008 0 0020 0 080 0 0031 Crankshaft journal O D 47 965 47 980 1 8884 1 8890 Crankshaft thrust bearing th...

Page 476: ... 984 0 5495 0 5506 Clutch release cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston diam 38 042 38 075 1 4977 1 4990 ITEM STANDARD LIMIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 133 30 30 17 15 Final reduction ratio 3 090 34 11 Gear ratios Low 2 285 32 14 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0 851 23 27 Shift fork to groove clearance No ...

Page 477: ... Jet needle J N 5D35 1st 5D47 1st Needle jet N J Throttle valve Th V 125 110 Pilot jet P J Pilot screw P S PRE SET PRE SET Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION E 28 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E4 Idle r min 1 200 100 r min Float height 27 7 1 0 mm 1 09 0 04 in 9 1 1 0 mm 0 36 0 04 in Main jet M J 132 5 127 5 Jet needle J...

Page 478: ...Type N G K DPR8EA 9 N D X24EPR U9 Gap 0 8 0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm Signal coil resistance Approx 50 200 Ω G Bl Ignition coil resistance Primary 2 6 Ω tap tap Secondary 15 40 kΩ Plug cap tap Generator no load voltage When engine cold More than 75 V AC at 5 000 r min Generator Max output 250 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brus...

Page 479: ... pedal free travel 20 30 0 8 1 2 Rear brake pedal height 40 1 6 Brake lining thickness Rear 1 5 0 056 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 5 0 0 2 0 20 0 01 4 5 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4993 Brake caliper cylinder bore Front 42 850 42 926 1 6870 1 6900 Brake...

Page 480: ...pth Front 1 6 0 06 Rear 2 0 0 08 ITEM STANDARD LIMIT NOTE Front fork stroke 130 5 12 Front fork spring free length 348 3 13 71 Front fork oil level 124 3 4 89 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 30 0 012 COLD INFLATION TIRE PRESSURE NORMAL RIDING SOLO RIDING DUAL RIDING kPa kg cm2 psi kPa kg cm2 psi FRONT 200 2 00 29 225 2 25 33 REAR 225 2 25 33 250 2 50 36 ...

Page 481: ...F or SG Engine oil capacity Change 2 400 ml 2 5 2 1 US lmp qt Filter change 2 800 ml 3 0 2 5 US lmp qt Overhaul 3 300 ml 3 5 2 9 US lmp qt Front fork oil type Fork oil 10 Front fork oil capacity each leg 413 ml 14 0 14 5 US lmp oz Final bevel gear oil type SAE 90 hypoid gear oil with GL 5 under API classification Final bevel gear oil capacity 200 220 ml 6 8 7 0 7 4 7 7 US lmp oz Brake fluid type D...

Page 482: ... W W Y B W W Lg B W Gr Lg B W Gr B G B W Lg Lbl B O R W Y Y W B G B W Lg Lbl B O R W Y Y W B G B W Lg Lbl B O R W Y Y W B G B W Lg Lbl B O R W Y Y W Bl G Y Y Y Bl G Y Y Y Y G B W O Y B Y Y G B W O Y B Y Br Lbl G O Y O Y B R W B Y O W B W Bl G Br Lbl G O Y O Y B R W B Y O W B W Bl G Y Y Y O B R B W Y Y Y O B R B W B Lbl Lg B R O W O W B Y G B Lbl Lg B R O W O W B Y G R Y G B W B Br B W R R Y G B W ...

Page 483: ...LDER INSTALLATION 23 14 EVAPORATIVE EMISSION CONTROL SYSTEM FOR E 33 23 15 WIRING DIAGRAM 23 16 VS800K5 05 MODEL 23 1 This chapter describes service data service specifications and servicing procedures which differ from those of the VS800GLK4 04 MODEL NOTE Please refer to chapters 1 through 22 for details which are not given in this chapter NOTE Asterisk mark indicates the new K5 model specificati...

Page 484: ...spension stroke 130 mm 5 1 in Rear wheel travel 90 mm 3 5 in Caster 32 40 Trail 138 mm 5 43 in Steering angle 40 right left Turning radius 2 9 m 9 5 ft Front brake Disc brake Rear brake Drum brake Front tire size 100 90 19 M C 57H tube type Rear tire size 140 90 15 M C 70H tube type ELECTRICAL Ignition type Electronic ignition Transistorized Ignition timing 5 B T D C at 1 200 r min Spark plug NGK ...

Page 485: ...tem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem and length IN EX 4 0 0 16 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length INNER 38 3 1 51 OUTER 40 1 1 58 Valve spring tension INNER 64 73 N 6 51 7 49 kgf 14 35 16 51 lbs at length 32 5 mm 1...

Page 486: ...ylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 300 1 600 kPa 13 16 kgf cm2 185 228 psi 1 100 kPa 11 kgf cm2 156 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 Cylinder bore 83 000 83 015 3 2677 3 2683 83 085 3 2711 Piston diam 82 950 82 965 3 26...

Page 487: ...learance 0 10 0 20 0 004 0 008 0 30 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 0009 0 0017 0 080 0 0031 Crank pin O D 40 982 41 000 1 6135 1 6142 Crankshaft journal oil clearance 0 020 0 050 0 0008 0 0020 0 080 0 0031 Crankshaft journal O D 47 965 47 980 1 8884 1 8890 Crankshaft thrust bearing thickness 1 92...

Page 488: ...0 5506 Clutch release cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston diam 38 042 38 075 1 4977 1 4990 ITEM STANDARD LIMIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 133 30 30 17 15 Final reduction ratio 3 090 34 11 Gear ratios Low 2 285 32 14 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0 851 23 27 Shift fork to groove clearance No 1 0 10 0 30 ...

Page 489: ... 36 0 04 in Main jet M J Jet needle J N 5D35 1st 5D47 1st Needle jet N J Throttle valve Th V 125 110 Pilot jet P J Pilot screw P S PRE SET PRE SET Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION E 33 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E5 Idle r min 1 200 50 r min Float height 27 7 1 0 mm 1 09 0 04 in 9 1 1 0 mm 0 36 0 04 in Main jet M J J...

Page 490: ...kΩ Plug cap tap Generator no load voltage When engine cold More than 75 V AC at 5 000 r min Generator Max output 250 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length Limit 9 0 0 35 N D Commutator under cut Limit 0 2 0 008 Starter relay resistance 2 6 Ω Battery Type designation YB16B A1 Capacity 12 V 57 6 kC 16 Ah 10 HR Standard electrolyte S G 1 28 at 20 C 6...

Page 491: ...travel 20 30 0 8 1 2 Rear brake pedal height 40 1 6 Brake lining thickness Rear 1 5 0 056 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 5 0 0 2 0 20 0 01 4 5 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4993 Brake caliper cylinder bore Front 42 850 42 926 1 6870 1 6900 Brake caliper pis...

Page 492: ...ITEM STANDARD LIMIT NOTE Front fork stroke 130 5 12 Front fork spring free length 363 3 14 3 356 14 0 Front fork oil level 118 4 73 Front fork inner tube O D 39 1 5 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 30 0 012 COLD INFLATION TIRE PRESSURE NORMAL RIDING SOLO RIDING DUAL RIDING kPa kgf cm2 psi kPa kgf cm2 psi FRONT 200 2 00 29 225 2 25 33 REAR 225 2 25 33 250 2 50 36 ...

Page 493: ...ngine oil capacity Change 2 400 ml 2 5 2 1 US lmp qt Filter change 2 800 ml 3 0 2 5 US lmp qt Overhaul 3 300 ml 3 5 2 9 US lmp qt Front fork oil type Fork oil 10 Front fork oil capacity each leg 418 ml 14 1 14 7 US lmp oz Final bevel gear oil type SAE 90 hypoid gear oil with GL 5 under API classification Final bevel gear oil capacity 200 220 ml 6 8 7 0 7 4 7 7 US lmp oz Brake fluid type DOT 4 Cool...

Page 494: ...tor lead wire Except E 33 Handlebar switch R L Clutch hose Wiring harness speedometer Clamp Pass the lead wire hole of the upper bracket Clamp Wiring harness Clamp the throttle position switch lead wire Throttle position switch Fuel hose I g coil Generator lead wire Starter relay Pass the regulator rectifier lead wire between the fuse box and starter relay Pass the neutral switch and battery lead ...

Page 495: ...G Set the end fitting hex 17 part to set the end of the fuel tank bracket Parallel with the handle stay Clutch hose Carbureter Handle stay 28 Through the brake hose into the hole of the upper bracket Cushion Clutch hose ...

Page 496: ...FRONT BRAKE HOSE ROUTING HANDLE BALANCER INSTALLATION TOOL HOLDER INSTALLATION 21 Parallel with handle stay 1 mm 35 5 mm ...

Page 497: ...VE EMISSION CONTROL SYSTEM FOR E 33 Rear fender CANISTER COVER White paint is upward Clip end is forward Red paint is putside Red paint SURGE SIDE Clip end is backward White paint is outside Clip end is downward ...

Page 498: ...G Y G Y G Y G B B W B W Gr Gr B B W Gr Y B W B W W Y B W W Lg Lg B W B W Gr Gr Lg B W Gr B G B G B W B W Lg Lg Lb Lbl B O R O R W Y Y W Y W B G B W Lg Lbl B O R W Y Y W B G B G B W B W Lg Lg Lb Lbl B O R O R W Y Y W Y W B G B W Lg Lbl B O R W Y Y W Bl Bl G Y Y Y Bl G Y Y Y Y G Y G B W B W O Y O Y B Y B Y Y G B W O Y B Y Br Br Lb Lbl G O Y O Y O Y O Y B R B R W B Y B Y O W O W B W B W Bl Bl G Br Lb...

Page 499: ...AM 24 13 VS800K6 06 MODEL 24 1 This chapter describes service data service specifications and servicing procedures which differ from those of the VS800K5 05 MODEL NOTE Please refer to chapters 1 through 23 for details which are not given in this chapter NOTE Asterisk mark indicates the New K6 model service data ...

Page 500: ... Front suspension stroke 130 mm 5 1 in Rear wheel travel 90 mm 3 5 in Caster 32 40 Trail 138 mm 5 43 in Steering angle 40 right left Turning radius 2 9 m 9 5 ft Front brake Disc brake Rear brake Drum brake Front tire size 100 90 19 M C 57H tube type Rear tire size 140 90 15 M C 70H tube type ELECTRICAL Ignition type Electronic ignition Transistorized Ignition timing 5 B T D C at 1 200 r min Spark ...

Page 501: ... I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem and length IN EX 4 0 0 16 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length INNER 38 3 1 51 OUTER 40 1 1 58 Valve spring tension INNER 64 73 N 6 51 ...

Page 502: ... arm I D IN EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 966 11 984 0 4711 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 300 1 600 kPa 13 16 kgf cm2 185 228 psi 1 100 kPa 11 kgf cm2 156 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 ...

Page 503: ...040 0 7890 Conrod big end side clearance 0 10 0 20 0 004 0 008 0 30 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 0009 0 0017 0 080 0 0031 Crank pin O D 40 982 41 000 1 6135 1 6142 Crankshaft journal oil clearance 0 020 0 050 0 0008 0 0020 0 080 0 0031 Crankshaft journal O D 47 965 47 980 1 8884 1 8890 Cranksha...

Page 504: ...0 5506 Clutch release cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston diam 38 042 38 075 1 4977 1 4990 ITEM STANDARD LIMIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 133 30 30 17 15 Final reduction ratio 3 090 34 11 Gear ratios Low 2 285 32 14 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0 851 23 27 Shift fork to groove clearance No 1 0 10 0 30 ...

Page 505: ... 36 0 04 in Main jet M J Jet needle J N 5D35 1st 5D47 1st Needle jet N J Throttle valve Th V 125 110 Pilot jet P J Pilot screw P S PRE SET PRE SET Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION E 33 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E5 Idle r min 1 200 50 r min Float height 27 7 1 0 mm 1 09 0 04 in 9 1 1 0 mm 0 36 0 04 in Main jet M J J...

Page 506: ...0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm Signal coil resistance Approx 50 200 Ω G Bl Ignition coil resistance Primary 1 8 2 6 Ω tap tap Secondary 16 26 kΩ Plug cap tap Generator no load voltage When engine cold More than 75 V AC at 5 000 r min Generator Max output 250 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length Limit 9 0 0 35 N D Commutator...

Page 507: ...ravel 20 30 0 8 1 2 Rear brake pedal height 40 1 6 Brake lining thickness Rear 1 5 0 056 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 5 0 0 2 0 20 0 01 4 5 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4993 Brake caliper cylinder bore Front 42 850 42 926 1 6870 1 6900 Brake caliper pist...

Page 508: ... LIMIT NOTE Front fork stroke 130 5 12 Front fork spring free length 363 3 14 3 356 14 0 Front fork oil level 118 4 6 Front fork inner tube O D 39 1 5 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 30 0 012 COLD INFLATION TIRE PRESSURE NORMAL RIDING SOLO RIDING DUAL RIDING kPa kgf cm2 psi kPa kgf cm2 psi FRONT 200 2 00 29 225 2 25 33 REAR 225 2 25 33 250 2 50 36 ...

Page 509: ...4 US lmp gal E 33 12 0 L 3 2 2 6 US lmp gal Others reserve 3 0 L 0 8 0 7 US lmp gal Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 2 400 ml 2 5 2 1 US lmp qt Filter change 2 800 ml 3 0 2 5 US lmp qt Overhaul 3 300 ml 3 5 2 9 US lmp qt Front fork oil type Fork oil 10 Front fork oil capacity each leg 418 ml 14 1 14 7 US lmp oz Final bevel gear oil type SAE 90 h...

Page 510: ... one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 1 4 V and more tester s battery voltage NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace the battery WIRE COLOR B Black B R Black with Red tracer B W Black with White tracer Probe of tester to Probe of tester to B1 B2 B3 B W B R B1 0 3 0 6 B2 0 3 0 6 B3 0 3 0 6 B W B R 0 3 0 ...

Page 511: ...G Y G Y G B B W B W Gr Gr B B W Gr Y B W B W W Y B W W Lg Lg B W B W Gr Gr Lg B W Gr B G B G B W B W Lg Lg Lb Lbl B O R O R W Y Y W Y W B G B W Lg Lbl B O R W Y Y W B G B G B W B W Lg Lg Lb Lbl B O R O R W Y Y W Y W B G B W Lg Lbl B O R W Y Y W Bl Bl G Y Y Y Bl G Y Y Y Y G Y G B W B W O Y O Y B Y B Y Y G B W O Y B Y Br Br Lb Lbl G O Y O Y O Y O Y B R B R W B Y B Y O W O W B W B W Bl Bl G Br Lbl G ...

Page 512: ...VS800K7 07 MODEL VS800K7 07 MODEL 25 1 This chapter describes service data service specifications and servicing procedures which differ from those of the VS800K6 06 MODEL Please refer to chapters 1 through 24 for details which are not given in this chapter ...

Page 513: ... Front suspension stroke 130 mm 5 1 in Rear wheel travel 90 mm 3 5 in Caster 32 40 Trail 138 mm 5 43 in Steering angle 40 right left Turning radius 2 9 m 9 5 ft Front brake Disc brake Rear brake Drum brake Front tire size 100 90 19 M C 57H tube type Rear tire size 140 90 15 M C 70H tube type ELECTRICAL Ignition type Electronic ignition Transistorized Ignition timing 5 B T D C at 1 200 r min Spark ...

Page 514: ... I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem and length IN EX 4 0 0 16 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length INNER 38 3 1 51 OUTER 40 1 1 58 Valve spring tension INNER 64 73 N 6 51 ...

Page 515: ... arm I D IN EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 966 11 984 0 4711 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 300 1 600 kPa 13 16 kgf cm2 185 228 psi 1 100 kPa 11 kgf cm2 156 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 ...

Page 516: ...040 0 7890 Conrod big end side clearance 0 10 0 20 0 004 0 008 0 30 0 012 Conrod big end width 21 95 22 00 0 864 0 866 Crank pin width 22 10 22 15 0 870 0 872 Conrod big end oil clearance 0 024 0 042 0 0009 0 0017 0 080 0 0031 Crank pin O D 40 982 41 000 1 6135 1 6142 Crankshaft journal oil clearance 0 020 0 050 0 0008 0 0020 0 080 0 0031 Crankshaft journal O D 47 965 47 980 1 8884 1 8890 Cranksha...

Page 517: ...0 5506 Clutch release cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston diam 38 042 38 075 1 4977 1 4990 ITEM STANDARD LIMIT Primary reduction ratio 1 690 71 42 Secondary reduction ratio 1 133 30 30 17 15 Final reduction ratio 3 090 34 11 Gear ratios Low 2 285 32 14 2nd 1 631 31 19 3rd 1 227 27 22 4th 1 000 25 25 Top 0 851 23 27 Shift fork to groove clearance No 1 0 10 0 30 ...

Page 518: ... 36 0 04 in Main jet M J Jet needle J N 5D35 1st 5D47 1st Needle jet N J Throttle valve Th V 125 110 Pilot jet P J Pilot screw P S PRE SET PRE SET Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION E 33 Carburetor type MIKUNI BS36SS No 1 MIKUNI BDS36SS No 2 Bore size 36 mm I D No 38E5 Idle r min 1 200 50 r min Float height 27 7 1 0 mm 1 09 0 04 in 9 1 1 0 mm 0 36 0 04 in Main jet M J J...

Page 519: ...0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm Signal coil resistance Approx 50 200 Ω G Bl Ignition coil resistance Primary 1 8 2 6 Ω tap tap Secondary 16 26 kΩ Plug cap tap Generator no load voltage When engine cold More than 75 V AC at 5 000 r min Generator Max output 250 W at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length Limit 9 0 0 35 N D Commutator...

Page 520: ...ravel 20 30 0 8 1 2 Rear brake pedal height 40 1 6 Brake lining thickness Rear 1 5 0 056 Brake drum I D Rear 180 7 7 11 Brake disc thickness Front 5 0 0 2 0 20 0 01 4 5 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4993 Brake caliper cylinder bore Front 42 850 42 926 1 6870 1 6900 Brake caliper pist...

Page 521: ... LIMIT NOTE Front fork stroke 130 5 12 Front fork spring free length 363 3 14 3 356 14 0 Front fork oil level 118 4 6 Front fork inner tube O D 39 1 5 Rear wheel travel 90 3 5 Swingarm pivot shaft runout 0 30 0 012 COLD INFLATION TIRE PRESSURE NORMAL RIDING SOLO RIDING DUAL RIDING kPa kgf cm2 psi kPa kgf cm2 psi FRONT 200 2 00 29 225 2 25 33 REAR 225 2 25 33 250 2 50 36 ...

Page 522: ...4 US lmp gal E 33 12 0 L 3 2 2 6 US lmp gal Others reserve 3 0 L 0 8 0 7 US lmp gal Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 2 400 ml 2 5 2 1 US lmp qt Filter change 2 800 ml 3 0 2 5 US lmp qt Overhaul 3 300 ml 3 5 2 9 US lmp qt Front fork oil type Fork oil 10 Front fork oil capacity each leg 418 ml 14 1 14 7 US lmp oz Final bevel gear oil type SAE 90 h...

Page 523: ...CONTENTS PAGE 26 1 VS800K8 08 MODEL NOTE The specifications and service data are the same as the K7 MODEL WIRING HARNESS ROUTING 26 2 26 VS800K8 08 MODEL ...

Page 524: ...stand relay Pass the starter motor lead wire as shown Pipe For E 33 Pass the wiring harness inside of the throttle cable Pass the ignition coil lead wire inside of regulator lead wire Except E 33 Handlebar switch R L Clutch hose Wiring harness speedometer Clamp Pass the handlebar switch lead wire hole of the upper bracket Clamp Wiring harness Clamp the throttle position switch lead wire Throttle p...

Page 525: ...Prepared by Printed in U S A Part No 99500 38062 03E 534 1990 ...

Page 526: ...Printed in USA F G H J K L M N P R S T V W X Y K1 K2 K3 K4 K5 K6 K7 K8 ...