Segment:
Mid-size cruiser motorcycle.
Target Audience:
Riders seeking a comfortable, stylish cruiser for touring and general riding.
Key Competitors:
Honda Shadow series, Yamaha Virago/V-Star series, Kawasaki Vulcan series.
Styling:
Classic cruiser aesthetics with a low seat height and prominent V-twin engine.
Ride Comfort:
Designed for comfortable long-distance riding with upright ergonomics.
Engine Character:
Torquey V-twin powerplant providing a satisfying riding experience.
Engine:
Detailed disassembly, assembly, inspection, and repair procedures for the V-twin engine.
Fuel System:
Carburetor tuning, fuel pump operation, fuel line routing, and troubleshooting.
Transmission:
Clutch operation, gear shifting mechanisms, gearbox disassembly and assembly, and lubrication.
Electrical System:
Wiring diagrams, component testing (ignition, lighting, charging system), battery maintenance, and starter motor troubleshooting.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber adjustment and replacement, and swingarm maintenance.
Brakes:
Front and rear brake caliper servicing, master cylinder overhaul, brake pad replacement, and bleeding procedures.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat servicing, and handlebar adjustments.
Wheels And Tires:
Wheel bearing maintenance, tire mounting and balancing, and spoke tensioning (if applicable).
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and common problem diagnosis for engine, electrical, and mechanical systems.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Adjustment Procedures:
Carburetor synchronization, clutch adjustment, throttle cable adjustment, and idle speed settings.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Diagnostics:
Systematic approach to diagnosing common malfunctions with symptoms and likely causes.
Diagnostic Capabilities:
Covers basic diagnostic procedures and troubleshooting for most common issues encountered by DIY mechanics.
Rebuild Level:
Sufficient detail for complete engine and transmission rebuilds for experienced DIYers or professional mechanics.
Component Diagrams:
Includes detailed exploded view diagrams for most components, aiding in assembly and disassembly.
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick access to specific topics and procedures.
Print Quality:
High-resolution scans with clear text and diagrams, suitable for printing.
Accessibility:
Accessible on computers, tablets, and smartphones.
Digital Access:
Instant download access after purchase.
Digital Content:
Digital replica of the original factory service manual.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, 4-valve, V-twin
Displacement:
805 cc (49.1 cu in)
Bore X Stroke:
92.0 mm x 75.0 mm (3.62 in x 2.95 in)
Horsepower:
Approx. 50 HP (37 kW) @ 6,500 RPM (Estimated)
Torque:
Approx. 65 Nm (48 lb-ft) @ 5,000 RPM (Estimated)
Fuel Delivery:
Two Mikuni 36 mm constant velocity carburetors
Fuel Tank Capacity:
16.0 L (4.2 US gal)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Safety Features Overview:
Standard safety features for motorcycles of this era, focusing on braking and stability.
Braking System:
Front: Hydraulic disc; Rear: Hydraulic disc.
Lighting:
Halogen headlight, taillight, and turn signals.
Frame Construction:
Steel double-cradle frame for structural integrity.
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as needed based on inspection.
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain.
Engine Oil Type:
Suzuki recommended 4-stroke motorcycle oil, API SE, SF, SG, SH, SJ, or higher; JASO MA certified. Viscosity: SAE 10W-40.
Engine Oil Capacity:
3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change.
Fork Oil Type:
SAE 10W or equivalent (Refer to manual for exact type and quantity).
Brake Fluid:
DOT 4 (Consult manual for specific recommendations).
Carburetor Synchronization:
Can require periodic synchronization for smooth running, especially after extended use.
Rear Drive Shaft Lubrication:
Regular lubrication of the drive shaft and U-joint is crucial for longevity. This manual will detail the procedure.
Idle Stability:
Some units may experience occasional minor fluctuations in idle speed, often addressable through carburetor adjustments.
Suzuki Motorcycles:
Suzuki Motor Corporation has a long history of producing reliable and innovative motorcycles across various segments.
Marauder Lineage:
The VZ800 Marauder was part of Suzuki's cruiser lineup, offering a more stylized alternative to traditional cruisers. It evolved from earlier models like the Intruder series.
Production Years:
The VZ800 Marauder was produced from 1997 to 2004.
Manufacturing Location:
Japan
