Suzuki VS700 Service Manual
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Suzuki VS700 Service Manual

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Table of Contents

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VS700/750/800
Service
Manual
*99500-38062-03E*
* 9 9 5 0 0 - 3 8 0 6 3 - 0 3 E *

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Summary of Contents for Suzuki VS700

  • 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: Engine

    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 emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN.
  • Page 5 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE SHAFT DRIVE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM EMISSION CONTROL INFORMATIONS ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION...

  • Page 6: Table Of Contents

    SUPPLEMENTS VS700GLE VS700GLH (’87-MODEL) VS750GLJ (’88-MODEL) VS750GLK (’89-MODEL) VS750GLFL/GLPL (’90-MODEL) VS750GLFM/GLPM (’91-MODEL) VS800GLN (’92-MODEL) VS800GLP/R (’93/’94-MODEL) VS800GLS (’95-MODEL) VS800GLT/V (’96/’97-MODEL) VS800GLW/X (’98/’99-MODEL) VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) VS800GLK4 (’04-MODEL) VS800K5 ('05-MODEL) VS800K6 ('06-MODEL) VS800K7 ('07-MODEL) VS800K8 ('08-MODEL)
  • Page 273 VS700GLE...
  • Page 294 VS700GLH ('87-MODEL)
  • Page 318 VS750GLJ ('88-MODEL)
  • Page 344 VS750GLK ('89-MODEL)
  • Page 363 VS800GLN ('92-MODEL)
  • Page 394 VS800GLP/R ('93/94-MODEL)
  • Page 406 VS800GLS ('95-MODEL)
  • Page 422 VS800GLT/V ('96/'97-MODEL)
  • Page 443 VS800GLW/X ('98/'99-MODEL)
  • Page 456 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) This section describes service data and service specifications which differ from those 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...

  • Page 457: Chassis

    21-1 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................* 2 250 mm (88.6 in) Overall width ................. * 885 mm (34.8 in) Overall height ................* 1 180 mm (46.5 in) Wheelbase ..................1 560 mm (61.4 in) Ground clearance .................

  • Page 458: Vs800Gly/K1/K2/K3 ('00/'01/'02/'03-Model)

    VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-2 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.18) ——— (1.02) Valve lift ——— (0.33) ——— (0.33) Valve clearance 0.08 – 0.13 ——— IN. & EX. (when cold) (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 459 21-3 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) ITEM STANDARD LIMIT Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013-0.0026) (0.0059) Camshaft journal holder I.D. No.1 Left side 20.012 – 20.025 ——— No.2 Right side (0.7879-0.7884) No.1 Right side 25.012 – 25.025 ——— No.2 Left side (0.9847-0.9852) Camshaft journal O.D.
  • Page 460 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-4 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 ——— (0.0398 – 0.0406) 1.21 – 1.23 ——— (0.0476 – 0.0484) 2.51 – 2.53 ——— (0.0988-0.0996) Piston ring thickness 0.970 – 0.990 ——— (0.0382 – 0.0390) 1.170 – 1.190 ———...
  • Page 461 21-5 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 – 3.08 2.62 No.1 (0.115 – 0.121) (0.103) 3.45 – 3.55 3.15 No.2 (0.136 – 0.140) (0.124) Drive plate claw width 15.8 – 16.0 15.0 (0.622 – 0.630) (0.591) Driven plate distortion 0.10...
  • Page 462 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-6 SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 ——— (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.064 Drive side ——— (0.001 – 0.025) CARBURETOR SPECIFICATION ITEM E-02, 04, 25, 34 Carburetor type MIKUNI BS36SS (No.1) MIKUNI BDS36SS (No.2)
  • Page 463 21-7 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) CARBURETOR SPECIFICATION ITEM E-18 Carburetor type MIKUNI BS36SS (No.1) MIKUNI BDS36SS (No.2) ← Bore size 36 mm ← I.D. No. 38E2 ← Idle r/min. 1 200 ± 50 r/min. Float height 27.7 ± 1.0 mm 9.1 ± 1.0 mm (1.09 ±...
  • Page 464 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-8 CARBURETOR SPECIFICATION ITEM 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 9.1 ± 1.0 mm (1.09 ±...
  • Page 465 21-9 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) CARBURETOR SPECIFICATION ITEM E-37, P-37 Carburetor type MIKUNI BS36SS (No.1) MIKUNI BDS36SS (No.2) ← Bore size 36 mm ← I.D. No. 38EB ← Idle r/min. 1 100 ± 100 r/min. Float height 27.7 ± 1.0 mm 9.1 ± 1.0 mm (1.09 ±...
  • Page 466 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-10 WATTAGE Unit: W SPECIFICATION ITEM E-02 E-03, 28, 33 The others ← ← Headlight ← ← Parking light ← ← Brake light/Taillight 21/5 Turn signal light 21/5 (Front), 21 (Rear) ← ← Speedometer light ← ← Water temp. meter light ←...
  • Page 467 21-11 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) ITEM STANDARD LIMIT Tire size Front *100/90-19 M/C 57H ——— Rear 140/90-15 M/C 70H ——— Tire tread depth Front ——— (0.06) Rear ——— (0.08) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke ——— (5.12) Front fork spring free length 348.3 ———...
  • Page 468 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-12 FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Use only unleaded gasoline of at least 87 pump Fuel type R + M octane ( ) or 91 octane or higher rated by the research method. U.S.A. and Gasoline containing MTBE (MethyI Tertiary ButyI Canada Ether), less than 10% ethanol, or less than 5%...

  • Page 469: Steering Stem

    21-13 VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) STEERING STEM CONSTRUCTION 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...

  • Page 470: Cable Routing

    VS800GLY/K1/K2/K3 (’00/’01/’02/’03-MODEL) 21-14 CABLE ROUTING Wiring harness Wiring harness Clamp...

  • Page 471: Vs800Glk4 ('04-Model)

    VS800GLK4 (’04-MODEL) 22-1 VS800GLK4 (’04-MODEL) This chapter describes 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. CONTENTS SPECIFICATIONS ..................22- 2 SERVICE DATA ....................22- 3...
  • Page 472 22-2 VS800GLK4 (’04-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 250 mm (88.6 in) Overall width ..................885 mm (34.8 in) Overall height ..................1 180 mm (46.5 in) Wheelbase ..................1 560 mm (61.4 in) Ground clearance ................125 mm ( 4.9 in) Seat height ..................
  • Page 473 VS800GLK4 (’04-MODEL) 22-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.18) — (1.02) Valve lift — (0.33) — (0.33) Valve clearance 0.08 – 0.13 IN. & EX. — (when cold) (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 474 22-4 VS800GLK4 (’04-MODEL) STANDARD ITEM LIMIT Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0060) Camshaft journal holder I.D. No. 1 Left side 20.012 – 20.025 — No. 2 Right side (0.7879 – 0.7884) No. 1 Right side 25.012 –...
  • Page 475 VS800GLK4 (’04-MODEL) 22-5 STANDARD ITEM LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 –...
  • Page 476 22-6 VS800GLK4 (’04-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.45 – 3.55 3.15 No. 2 (0.136 – 0.140) (0.124) Drive plate claw width 15.8 – 16.0 15.0 (0.622 –...
  • Page 477 VS800GLK4 (’04-MODEL) 22-7 SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.64 — Drive side (0.001 – 0.025) CARBURETOR SPECIFICATION ITEM E-03 Carburetor type MIKUNI BS36SS (No.
  • Page 478 22-8 VS800GLK4 (’04-MODEL) CARBURETOR SPECIFICATION ITEM 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 ±...
  • Page 479 VS800GLK4 (’04-MODEL) 22-9 WATTAGE Unit: W ITEM SPECIFICATION Headlight Parking light Brake light/Taillight 21/5 Turn signal light 21/5 (Front), 21 (Rear) Speedometer light Water temp. meter light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light License light BRAKE + WHEEL Unit: mm (in)
  • Page 480 22-10 VS800GLK4 (’04-MODEL) STANDARD ITEM LIMIT Tire size Front 100/90-19 57H, 100/90-19M/C 57H — Rear 140/90-15 70H, 140/90-15M/C 70H — Tire tread depth Front — (0.06) Rear — (0.08) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke —...
  • Page 481 VS800GLK4 (’04-MODEL) 22-11 FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...

  • Page 482: Wiring Diagram

    22-12 VS800GLK4 (’04-MODEL) WIRING DIAGRAM...

  • Page 483: Vs800K5 ('05-Model)

    VS800K5 ('05-MODEL) 23-1 VS800K5 ('05-MODEL) 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. CONTENTS PAGE SPECIFICATIONS..................
  • Page 484 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 250 mm (88.6 in) Overall width..................* 765 mm (30.1 in) Overall height ..................* 1 125 mm (44.3 in) Wheelbase ..................1 560 mm (61.4 in) Ground clearance................125 mm ( 4.9 in) Seat height ..................
  • Page 485 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM LIMIT STANDARD Valve diam. — (1.18) — (1.02) Valve lift — (0.33) — (0.33) Valve clearance 0.08 – 0.13 IN. & EX. — (when cold) (0.003 – 0.005) Valve guide to valve stem 0.010 –...
  • Page 486 ITEM STANDARD LIMIT Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0060) Camshaft journal holder I.D. No. 1 Left side 20.012 – 20.025 — No. 2 Right side (0.7879 – 0.7884) No. 1 Right side 25.012 – 25.025 —...
  • Page 487 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 – 0.990 — (0.0382 – 0.0390) 1.170 – 1.190 —...
  • Page 488 CLUTCH Unit: mm (in) STANDARD ITEM LIMIT Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.45 – 3.55 3.15 No. 2 (0.136 – 0.140) (0.124) Drive plate claw width 15.8 – 16.0 15.0 (0.622 – 0.630) (0.591) Driven plate distortion 0.10...
  • Page 489 SHAFT DRIVE Unit: mm (in) STANDARD ITEM LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.64 Drive side — (0.001 – 0.025) CARBURETOR SPECIFICATION ITEM E-03, 28 Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No.
  • Page 490 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order 1·2 Spark plug N.G.K.: DPR8EA-9 Type N.D.: X24EPR-U9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. Approx. 50 – 200 Ω (G – Bl) Signal coil resistance * 1.8 –...
  • Page 491 WATTAGE Unit: W SPECIFICATION ITEM Headlight Parking light Brake light/Taillight 21/5 Turn signal light 21/5 (Front), 21 (Rear) Speedometer light Water temp. meter light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light License light BRAKE + WHEEL Unit: mm (in) ITEM...
  • Page 492 ITEM STANDARD LIMIT Tire size Front 100/90-19 57H, 100/90-19M/C 57H — Rear 140/90-15 70H, 140/90-15M/C 70H — Tire tread depth Front — (0.06) Rear — (0.08) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (5.12) Front fork spring free length 363.3 (14.3) (14.0)
  • Page 493 FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
  • Page 494 WIRING HARNESS ROUTING Coupler holder Clamp Clamp Wiring harness Tail/Brake light Tail/Brake light License plate light Clamp Battery lead wire Rear turn signal light (R & L) Wiring Ignition coil lead wire To rear turn harness signal light (R) Ignitor Slit is To right handlebar lower side.

  • Page 495: Clutch Hose Routing

    CLUTCH HOSE ROUTING Parallel with the handle stay. Handle stay 28˚ Carbureter Through the brake hose into the hole of the upper bracket. Set the end-fitting hex 17 part to set the end of the fuel tank bracket. Clutch hose Clutch hose Cushion...

  • Page 496: Front Brake Hose Routing

    FRONT BRAKE HOSE ROUTING Parallel with handle stay. 21˚ HANDLE BALANCER INSTALLATION 1 mm 35.5 mm TOOL HOLDER INSTALLATION...
  • Page 497 EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33) Rear fender Clip end is backward. White paint is outside. Clip end is downward. CANISTER Red paint (SURGE SIDE) Clip end is forward. Red paint is putside. White paint is upward. COVER...
  • Page 498 WIRING DIAGRAM...

  • Page 499: Vs800K6 ('06-Model)

    VS800K6 ('06-MODEL) 24-1 VS800K6 ('06-MODEL) 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. CONTENTS PAGE SPECIFICATIONS..................
  • Page 500 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 250 mm (88.6 in) Overall width................765 mm (30.1 in) Overall height ................1 125 mm (44.3 in) Wheelbase ................1 560 mm (61.4 in) Ground clearance..............125 mm ( 4.9 in) Seat height ................
  • Page 501 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM LIMIT STANDARD Valve diam. — (1.18) — (1.02) Valve lift — (0.33) — (0.33) Valve clearance 0.08 – 0.13 IN. & EX. — (when cold) (0.003 – 0.005) Valve guide to valve stem clear- 0.010 –...
  • Page 502 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.954 – 35.994 35.660 (1.4155 – 1.4171) (1.4039) 36.919 – 36.959 36.620 (1.4535 – 1.4551) (1.4417) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0060) Camshaft journal holder I.D.
  • Page 503 ITEM STANDARD LIMIT Piston ring to groove clearance 0.180 — (0.007) 0.150 — (0.006) Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 –...
  • Page 504 CLUTCH Unit: mm (in) STANDARD ITEM LIMIT Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.45 – 3.55 3.15 No. 2 (0.136 – 0.140) (0.124) Drive plate claw width 15.8 – 16.0 15.0 (0.622 – 0.630) (0.591) Driven plate distortion 0.10...
  • Page 505 SHAFT DRIVE Unit: mm (in) ITEM STANDARD LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.64 — Drive side (0.001 – 0.025) CARBURETOR SPECIFICATION ITEM E-03, 28 Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No.
  • Page 506 THERMOSTAT + RADIATOR + FAN ITEM STANDARD LIMIT Thermostat valve opening tempera- 75.0 ± 1.5 °C (167 ± 2.7 °F) — ture Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — Radiator cap valve release pres- 110 ±...
  • Page 507 WATTAGE Unit: W SPECIFICATION ITEM Headlight Parking light Brake light/Taillight 21/5 Turn signal light 21/5 (Front), 21 (Rear) Speedometer light Water temp. meter light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light License light BRAKE + WHEEL Unit: mm (in) ITEM...
  • Page 508 ITEM STANDARD LIMIT Tire size Front 100/90-19M/C 57H — Rear 140/90-15M/C 70H — Tire tread depth Front — (0.06) Rear — (0.08) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (5.12) Front fork spring free length 363.3 (14.3) (14.0)
  • Page 509 FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.
  • Page 510 REGULATOR/RECTIFIER • Remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. ! 09900-25008: Multi-circuit tester set "...
  • Page 511 WIRING DIAGRAM...

  • Page 512: Vs800K7 ('07-Model)

    VS800K7 ('07-MODEL) 25-1 VS800K7 ('07-MODEL) 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. CONTENTS PAG E SPECIFICATIONS..................
  • Page 513 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 250 mm (88.6 in) Overall width................765 mm (30.1 in) Overall height ................1 125 mm (44.3 in) Wheelbase ................1 560 mm (61.4 in) Ground clearance..............125 mm (4.9 in) Seat height ................
  • Page 514 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM LIMIT STANDARD Valve diam. — (1.18) — (1.02) Valve lift — (0.33) — (0.33) Valve clearance 0.08 – 0.13 IN. & EX. — (when cold) (0.003 – 0.005) Valve guide to valve stem clear- 0.010 –...
  • Page 515 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 35.954 – 35.994 35.660 (1.4155 – 1.4171) (1.4039) 36.919 – 36.959 36.620 (1.4535 – 1.4551) (1.4417) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0060) Camshaft journal holder I.D.
  • Page 516 ITEM STANDARD LIMIT Piston ring to groove clearance 0.180 — (0.007) 0.150 — (0.006) Piston ring groove width 1.01 – 1.03 — (0.0398 – 0.0406) 1.21 – 1.23 — (0.0476 – 0.0484) 2.51 – 2.53 — (0.0988 – 0.0996) Piston ring thickness 0.970 –...
  • Page 517 CLUTCH Unit: mm (in) STANDARD ITEM LIMIT Drive plate thickness 2.92 – 3.08 2.62 No. 1 (0.115 – 0.121) (0.103) 3.45 – 3.55 3.15 No. 2 (0.136 – 0.140) (0.124) Drive plate claw width 15.8 – 16.0 15.0 (0.622 – 0.630) (0.591) Driven plate distortion 0.10...
  • Page 518 SHAFT DRIVE Unit: mm (in) STANDARD ITEM LIMIT Secondary bevel gear backlash 0.05 – 0.32 — (0.002 – 0.013) Final bevel gear backlash 0.03 – 0.64 Drive side — (0.001 – 0.025) CARBURETOR SPECIFICATION ITEM E-03, 28 Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No.
  • Page 519 THERMOSTAT + RADIATOR + FAN ITEM STANDARD LIMIT Thermostat valve opening tempera- 75.0 ± 1.5 °C (167 ± 2.7 °F) — ture Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) — Radiator cap valve release pres- 110 ±...
  • Page 520 WATTAGE Unit: W SPECIFICATION ITEM Headlight Parking light Brake light/Taillight 21/5 Turn signal light 21/5 (Front), 21 (Rear) Speedometer light Water temp. meter light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light License light BRAKE + WHEEL Unit: mm (in) ITEM...
  • Page 521 ITEM STANDARD LIMIT Tire size Front 100/90-19M/C 57H — Rear 140/90-15M/C 70H — Tire tread depth Front — (0.06) Rear — (0.08) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (5.12) Front fork spring free length 363.3 (14.3) (14.0)
  • Page 522 FUEL + OIL + COOLANT ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.

  • Page 523: Vs800K8 ('08-Model)

    VS800K8 ('08-MODEL) 26-1 VS800K8 ('08-MODEL) NOTE: The specifications and service data are the same as the K7-MODEL. CONTENTS PAG E WIRING HARNESS ROUTING ..............26-2...
  • Page 524 26-02 VS800K8 (’08 MODEL) WIRING HARNESS ROUTING Coupler holder Clamp Clamp Wiring harness Tail/Brake light Tail/Brake light License plate light Clamp Battery - lead wire Rear turn signal light (R & L) Wiring Ignition coil lead wire To rear turn harness signal light (R) Ignitor...
  • Page 525 Prepared by 1990 Part No. 99500-38062-03E Printed in U.S.A.
  • 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...

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