Suzuki VX800 Service Repair Manual 93-ON

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🏷️ Basic Information Identification Make: Suzuki Model: VX800 Model Designation: Intruder 800 / Marauder 800 (North America) Chassis Code: VS750GLF / VS800GL Codes Product Code Interpretation: Likely refers to a...

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Type: Motorcycle

Vendor:

Sku: 264433

Tags: 1993 Motorcycle Motorcycles Suzuki VX800

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VX800

Model Designation:

Intruder 800 / Marauder 800 (North America)

Chassis Code:

VS750GLF / VS800GL

Codes

Product Code Interpretation:

Likely refers to a specific manual edition covering models from 1993 onwards.

👋 Introduction

Market Position

Vehicle Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a classic cruiser aesthetic with Suzuki's reliability, suitable for touring and cruising.

Competitive Analysis

Key Competitors:

Honda Shadow series, Yamaha Virago/V-Star series, Kawasaki Vulcan series.

Key Features

Engine Layout:

V-twin, liquid-cooled, offering strong low-end torque characteristic of cruisers.

Drivetrain:

Shaft drive, providing low maintenance compared to chain drive.

Styling:

Classic cruiser styling with pulled-back handlebars, forward-mounted footpegs, and often a teardrop fuel tank.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration.

Page Count

Estimated Page Count:

Hundreds of pages (specific number not provided but implies extensive content).

Manual Type

Manual Classification:

Service Repair Manual

Language

Language:

English (Assumed based on typical manual content and description)

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Powertrain Components:

Engine (V-twin, liquid-cooled), Transmission, Drivetrain (shaft drive).

Chassis And Suspension:

Frame, Front Suspension (telescopic forks), Rear Suspension (monoshock/dual shocks depending on specific variant/year), Swingarm.

Braking System:

Front and Rear Brake Systems (disc/drum configurations).

Electrical System:

Ignition System, Lighting, Charging System (stator, regulator/rectifier), Starting System, Wiring Diagrams, ECUs (if applicable).

Fuel System:

Carburetion (specific models), Fuel Injection (later models), Fuel Tank, Fuel Pump, Lines.

Cooling System:

Radiator, Coolant Lines, Water Pump (for liquid-cooled models).

Exhaust System:

Exhaust Headers, Mufflers, Gaskets.

Bodywork And Trim:

Fenders, Tank, Seats, Controls, Fairings/Cowlings (if applicable).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable), spark plug service, coolant checks, brake fluid replacement.

Component Disassembly And Assembly:

Step-by-step instructions for dismantling and reassembling major and minor components.

Troubleshooting Diagnostics:

Identification of common problems, diagnostic procedures, and repair solutions.

Rebuilding Procedures:

Detailed instructions for rebuilding engine components (e.g., carburetor, top-end), transmission, and suspension.

Electrical Troubleshooting:

Interpreting wiring diagrams, testing electrical circuits, diagnosing faults in ignition, charging, and lighting systems.

Suspension And Steering Service:

Fork seal replacement, shock absorber service, steering head bearing adjustment/replacement.

Brake System Overhaul:

Caliper service, master cylinder rebuild, bleeding procedures.

Technical Depth

Depth Of Information:

Highly detailed, suitable for novice to professional mechanics. Covers from basic adjustments to complete engine/transmission rebuilds.

Diagnostic Capability:

Includes diagnostic charts and procedures for identifying the root cause of malfunctions.

Special Tools Requirements:

Likely specifies required special tools for specific procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically, PDF manuals are text-searchable, allowing quick access to information.

Print Quality

Image Clarity:

High resolution images and diagrams are expected in a quality PDF manual.

Binding Type

Binding For Digital Format:

N/A (Digital Format)

Paper Type

Paper Type For Printed Version:

N/A (Digital Format)

Completeness

Manual Completeness:

Implied to be a complete manual covering all aspects of repair and maintenance.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, 2-valve per cylinder, V-twin

Displacement:

747cc (later models may have 805cc or similar).

Bore X Stroke:

79.0 mm x 76.0 mm (typical for 747cc, check specific year/model for exact figures)

Cooling System:

Liquid-cooled

Performance

Horsepower Estimate:

Approximately 50-60 HP (varies by year and tuning)

Torque Estimate:

Approximately 60-65 Nm (varies by year and tuning)

Fuel System

Carburetion Type:

Mikuni BS36 (typical for earlier models, dual carburetors)

Fuel Capacity:

13.5 Liters (approx. 3.6 US gal)

Ignition

Ignition System:

Electronic Ignition (Digital)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate

Final Drive:

Shaft drive

Features

Gear Ratios:

Specific ratios would be detailed in the manual, crucial for performance tuning.

📐 Dimensions

Exterior

Overall Length:

2270 mm (approx. 89.4 in)

Overall Width:

795 mm (approx. 31.3 in)

Overall Height:

1160 mm (approx. 45.7 in)

Wheelbase:

1595 mm (approx. 62.8 in)

Weights

Dry Weight:

Approx. 190 kg (419 lbs) (varies by year/trim)

Wet Weight:

Approx. 210 kg (463 lbs) (varies by year/trim)

Max Load:

Detailed in manual, typically around 180-200 kg for rider and passenger.

🛡️ Safety Features

Ratings

Safety Certifications:

N/A (Motorcycles typically don't have NHTSA-style safety ratings).

Active Features

Braking System Type:

Front: Disc, Rear: Drum (common on early models); Later models may feature rear disc as well.

Tire Specifications:

Front: 130/90-16, Rear: 170/80-15 (typical, check manual for exact fitment).

Passive Features

Frame Construction:

Steel double-cradle frame for stability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation).

Driver Assistance

Rider Assistance:

N/A (No electronic rider aids like ABS or traction control typically found on these models).

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Speedometer, Tachometer (on some models), Odometer, Trip Meter, Indicator Lights (oil pressure, neutral, turn signals, high beam).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact spec).

Valve Clearance Check:

Usually around 12,000 km (7,500 miles) or annually (critical for V-twin engines).

Coolant Change:

Every 2 years or as specified by coolant manufacturer/manual.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher (verify in manual).

Engine Oil Capacity:

Approx. 2.5 Liters (with filter change) (verify in manual).

Coolant Type:

Ethylene glycol-based coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 (verify in manual).

Final Drive Oil Type:

Gear oil (specific viscosity to be confirmed in manual).

Known Issues

Common Wear Items:

Brake pads, tires, clutch plates, fork seals, wheel bearings.

Carburetor Issues:

Can be prone to gumming if not run regularly or properly stored; requires periodic cleaning/rebuild.

Electrical Gremlins:

Aging wiring harnesses or regulator/rectifier failures can occur, typical for motorcycles of this era.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Legacy:

Suzuki has a long history in motorcycle manufacturing, known for innovation and performance across various segments.

Model Evolution

Vx800 Lineage:

Evolved from the VS750 Intruder, becoming a more popular and refined cruiser model with increased displacement and updated styling.

Production

Production Years:

Originally introduced in the late 1980s as the VS750 Intruder, with the VX800 designation (or VS800) continuing through the 1990s and into the early 2000s.

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Model Reception:

Generally well-regarded for its V-twin character, shaft drive reliability, and comfortable cruiser ergonomics. Often praised for value.

Ratings

Industry Reviews:

Contemporary reviews would highlight its smooth power delivery and competitor positioning. The manual's comprehensiveness directly aids in maintaining these positive attributes.