1997-2004 Suzuki VZ800 Marauder service manual

Product Information

Table of Contents

General Information

1. Introduction

   • Vehicle Identification
   • VIN Location
   • Model Identification

2. Specifications

   • General Specifications
   • Engine Specifications
   • Chassis Specifications

3. Maintenance Schedule

   • Periodic Maintenance Intervals
   • Maintenance Checklist

Periodic Maintenance

1. General Maintenance

   • Pre-Ride Inspection
   • Post-Ride Inspection

2. Lubrication

   • Lubrication Points
   • Recommended Lubricants

3. Adjustment Procedures

   • Valve Clearance Adjustment
   • Throttle Cable Adjustment

Engine

1. Engine Overview

   • Engine Construction
   • Engine Components

2. Engine Removal and Installation

   • Engine Removal Procedures
   • Engine Installation Procedures

3. Cylinder Head and Valves

   • Cylinder Head Removal
   • Valve Inspection and Adjustment

4. Piston and Crankshaft

   • Piston Removal and Inspection
   • Crankshaft Inspection

5. Engine Lubrication System

   • Oil Pump Inspection
   • Oil Filter Replacement

Fuel and Lubrication System

1. Fuel System Overview

   • Fuel Tank and Lines
   • Fuel Pump and Filter

2. Carburetor

   • Carburetor Adjustment
   • Carburetor Cleaning and Maintenance

3. Air Intake System

   • Air Filter Replacement
   • Air Intake Inspection

Cooling System

1. Cooling System Overview

   • Radiator and Hoses
   • Coolant Replacement

2. Thermostat and Temperature Control

   • Thermostat Inspection
   • Cooling Fan Operation

Chassis

1. Frame and Body

   • Frame Inspection
   • Body Panel Removal and Installation

2. Suspension

   • Front Fork Maintenance
   • Rear Shock Absorber Adjustment

3. Wheels and Tires

   • Wheel Inspection and Maintenance
   • Tire Pressure and Wear

4. Brakes

   • Brake Pad and Disc Inspection
   • Brake Fluid Replacement

Electrical System

1. Electrical System Overview

   • Battery Maintenance
   • Charging System Inspection

2. Ignition System

   • Spark Plug Inspection and Replacement
   • Ignition Coil Testing

3. Lighting and Signal Systems

   • Headlight and Taillight Maintenance
   • Signal Light Operation

4. Wiring Diagrams

   • Complete Vehicle Schematic
   • Component-Specific Diagrams

Servicing Information

1. Service Tools

   • Recommended Tools
   • Special Service Tools

2. Diagnostic Procedures

   • Troubleshooting Guide
   • Common Issues and Solutions

Emission Control Information

1. Emission System Overview

   • Emission Control Components
   • Emission Control Maintenance

2. Emission Standards

   • Compliance Information
   • Testing Procedures

Model-Specific Information

1. VZ800W ('98-Model)

   • Model-Specific Features
   • Maintenance Differences

2. VZ800/Y/K1/K2/K3 ('99, '00, '01, '02, '03-Models)

   • Model-Specific Features
   • Maintenance Differences

3. VZ800K4 ('04-Model)

   • Model-Specific Features
   • Maintenance Differences

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