Suzuki vl800 c50 service manual free download

Support the motorcycle so that the front wheel is off the ground. The locations of the following nuts and bolts on the motorcycle. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service.

This will give a good indication of the condition of the moving parts. Refer to the page listed in this section for removal and reinstallation instructions. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal pro- cedure. Caburetor removal! Once the nut has been removed, they are no longer of any use. Page 49 " Gearshift lever height A Standard: 90 mm 3.

NOTE: When loosen the rotor bolt, do not remove it. Replace either the cylinder head set or the camshaft if the clear- ance is incorrect. Sprocket side : The valve must be replaced if the runout exceeds the limit. Part No. Fit the valve and tap the coated seat with the valve face in a rotating man- ner, in order to obtain a clear impression of the seating contact.

In this operation, use the valve lapper to hold the valve head. Seat the pilot snugly. Rotate the cutter one or two turns. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length 1 will not be reduced to less than the service limit. Page Piston Diameter Service Limit: They bear the following identification numbers. SIZE 0. Oversize oil ring The following two types of oversize oil rings are available as op- 1. After placing the spacer, fit the two side rails 2.

NOTE: Side designations, top and bottom, are not applied to the spacer and side rails: you can position each either way. Using a small bore gauge, measure the conrod small end inside diameter.

Conrod small end I. Service Limit: Page 79 1 first and press in the other end. Crankshaft journal bearing I. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one.

Page 86 Before installing the gears, coat lightly moly paste or engine oil to the driveshaft and countershaft. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. The clearance for each of the three shifting forks plays an impor- tant role in the smoothness and positiveness of shifting action. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both.

Oil pressure switch: 14 N. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. Secondary gear case bolt Initial : 15 N.

Cam chain tensioner bolt: 10 N. Then tighten it 2 turns using the oil filter wrench. NOTE: The convex side of the washer faces outside. Clutch sleeve hub nut: 60 N.

Page " Chain tensioner lock tool Cam chain tension adjuster mounting bolt: 10 N. Use a new gasket to prevent gas leakage. Page Pull the cam chains upward, or the chain will be caught between crankcase and cam drive sprocket.

Also, apply engine oil onto the camshaft journal holders. NOTE: Arrow marks are located to forward. Front Rear No. Use two pieces of shims. Shim 1 size table Part number Thickness A-0A0 0. The secondary drive bevel gear service requires en- gine removal and disassembly. Refer to the engine removal and the engine disassembly sections for secondary drive bevel gear assembly removal. NOTE: Refer to the following pages for the details of each step. The removed bearing must be replaced with a new one.

NOTE: If no abnormal noise, the bearing removal is not necessary. Page ! Final gear case bolt: 23 N. If it is not within the specification, the shims must be changed. Pay attention to the following points. Use new O-ring and oil seat to prevent oil leakage. Use a new oil seal to prevent oil leakage. When installing the plate, fit the protrusion A of plate to the one of the bearing stopper grooves. NOTE: Two kinds of plates are available to lock the stopper at the proper position.

The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. Keep heat, sparks, and flames away from gasoline. Be careful not to scratch the fuel tank.

Clean the fuel filter with compressed air. Also check the fuel valve for cracks. NOTE: mark A on the fuel level gauge forward.

Face 10 N. Fuel level — The piston valve moves according to the negative pressure present on the downstream side of the venturi A. The fuel from the float chamber 2 is first passage and metered by the pilot jet 3 where it mixes with air coming in through 1 pilot air jet 4 and 2 pilot air jet 5. This causes the piston valve 2 moves upward.

The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel passes around main air bleed pipe 5, mixes with the air admitted through main air jet 6 to from an emulsion and emulsion fuel enters needle jet 7. The fuel then flows into the fuel pipe 4 and mixes with the air coming from the float chamber 2.

When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less. Use a new O-ring to prevent fuel leakage. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw. Carefully drill through the plug. Drill-stop Thread a self-tapping sheet metal screw into the plug. Make sure that the pressure build-up stops at 95— kPa 0.

Page Do not allow the switch to touch the pan, or false read- ing will result. NOTE: The stamped mark on the oil seal faces outside. Be careful not to scratch the rear fender. Be careful not to scratch the rear fenders. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual. Page Reassemble and remount the front wheel in the reverse order of removal and disassembly.

Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle. If any damages are found, replace the master cylinder with a new one.

Be careful not to scratch the front fender. NOTE: Be careful not to damage the inner tube. NOTE: Apply grease to the oil seal 4 lip lightly before installing it. NOTE: Hold the front fork upper cover to prevent it from falling. Page Apply grease to the O-ring and the final gear spline before install- ing the driven joint. Page Replace the brake shoes as a set, otherwise braking per- formance will be adversely affected.

NOTE: Slightly loosen the cushion rod mounting nuts and the shock ab- sorber lower mounting nut before removing the swingarm to fa If any de- fects are found, replace the spacers with new ones.

If an excessive play is noted, replace the bearing with a new one. Page When installing the bearings, stamped mark of bearing must face outside. Engage the universal joint to the propel- ler shaft first and then engage it to the secondary driven bevel gear shaft.

How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. Measure the voltage between the lead wires using the multi cir- cuit tester as indicated in the table below. Page Starter Motor Inspection Reassemble the starter motor in the reverse order of disassem- bly. For U. If the resistance is not within the specified value, replace the starter relay with a new one. NOTE: Make sure that the each spark plug cap and spark plug are con- nected properly.

Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one. When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

Check that the LED light immediately after turning the ignition switch on. Inspect the speed sensor and connection of couplers. If the speed sensor and connection is all right, replace the unit with a new one. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. Never remove the electrolyte container from the battery while there is still electrolyte in the container.

If the voltage reading is less than the Worn cylinder. Worn piston ring. Worn valve guide or improper valve seating. Repair or replace. Excessive valve chatter 1. Excessive valve clearance. Weak or broken valve spring. Worn camshaft. Worn or burnt camshaft journal. Noise seems to come from the piston 1. Worn gear. Worn or distorted gearshift fork.

Weakened gearshift stopper spring. Worn gearshift pawl. Engine idles poorly. Valve clearance out of adjustment. Carbon buildup on piston crown. Insufficient amount of engine oil.

Check level and add. Defective oil pump. Clogged oil circuit. Float chamber fuel level too low. Access this manual immediately on your internet browser on your mobile, desktop or tablet. Introduction Chapter 1: Routine maintenance and servicing Chapter 2: Engine, clutch and transmission Chapter 3: Cooling system Chapter 4: Part A: Fuel and exhaust systems - carbureted models Chapter 4: Part B: Fuel, engine management and exhaust systems - fuel injected models Chapter 5: Ignition system Chapter 6: Steering, suspension and final drive Chapter 7: Brakes, wheels and tires Chapter 8: Frame and bodywork Chapter 9: Electrical system.

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