Market Segment:
Cruiser Motorcycle
Target Audience:
Suzuki Marauder VZ800 owners, DIY enthusiasts, independent motorcycle repair shops
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series
Manual Value Proposition:
Authoritative and comprehensive resource for maintaining and repairing the 1999 Suzuki Marauder VZ800, reducing reliance on costly dealership services.
Vehicle Design Philosophy:
Classic cruiser styling with a focus on accessible V-twin power and comfortable riding.
Primary Coverage:
Repair, maintenance, troubleshooting, adjustments, disassembly, assembly, installation, removal
Secondary Coverage:
Wiring diagrams, specifications, diagnostic procedures
Estimated Pages:
300-500 (typical for this type of manual)
Type:
Factory Service Repair Manual
Engine Mechanical:
Disassembly, inspection, assembly of engine components (pistons, rings, cylinders, crankshaft, camshafts, valves, timing system)
Fuel System:
Carburetor service, fuel pump, fuel tank, fuel lines, fuel filter replacement
Ignition System:
Spark plugs, ignition coils, CDI unit, timing adjustment
Cooling System:
Radiator, fan, coolant hoses, thermostat, water pump
Transmission:
Clutch operation, gearbox disassembly and assembly, gear shifting mechanism
Drivetrain:
Shaft drive system, universal joints, final drive inspection
Brakes:
Front and rear brake systems, caliper service, master cylinder, brake fluid replacement, bleeding procedures
Suspension:
Front forks (oil change, seal replacement, spring inspection), rear shock absorber service, swingarm inspection
Steering:
Handlebar, steering stem, steering head bearing inspection and adjustment
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting, starting system, ignition switch, wiring diagrams
Bodywork And Frame:
Frame inspection, body panel removal and installation, seat, fuel tank removal
Routine Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable, though shaft drive), spark plug checks, air filter cleaning/replacement, brake pad inspection
Troubleshooting:
Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and mechanical issues
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacements, electrical system diagnostics and repair
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch cable adjustment, brake lever adjustment, steering head bearing adjustment
Diagnostic Charts:
Flowcharts and symptom-based troubleshooting guides for common issues.
Depth:
Comprehensive, covering basic to advanced repairs and diagnostics
Detail Level:
Step-by-step instructions with detailed torque specifications, clearances, and service limits
Engine Type:
V-twin, four-stroke
Displacement:
805 cc (49.1 cu in)
Bore X Stroke:
83.0 mm x 74.4 mm (3.27 in x 2.93 in)
Valvetrain:
SOHC, 3 valves per cylinder (2 intake, 1 exhaust)
Horsepower:
Approx. 55 hp (at crankshaft, estimates vary)
Torque:
Approx. 50 lb-ft (at crankshaft, estimates vary)
Carburetion:
Two Mikuni BSR34 carburetors
Fuel Capacity:
17 L (4.5 US gal)
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity:
3.2 L (3.4 US qt) with filter change
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every engine oil change (Suzuki Part No. 16510-07400 or equivalent).
Spark Plug Check:
Every 12,000 km (7,500 miles).
Air Filter Cleaning:
Every 6,000 km (3,700 miles); replace if damaged.
Brake Fluid Replacement:
Every 2 years or as needed (DOT 4 recommended).
Fork Oil Change:
Every 12,000 km (7,500 miles) or 12 months.
Front Fork Oil:
Suzuki Fork Oil SS-05 (or equivalent SAE 5W oil), 508 ml per fork leg.
Common Complaints:
Carburetor synchronization issues, potential rear brake fade under heavy use, stator or regulator/rectifier failure (common in many motorcycles of this era), minor electrical gremlins.
Manufacturer:
Suzuki Motor Corporation, a Japanese multinational corporation known for a wide range of products including motorcycles, automobiles, ATVs, and marine engines.
Marauder Lineage:
The VZ800 Marauder was part of Suzuki's cruiser lineup, designed to offer a larger displacement V-twin in a stylish package, competing with other manufacturers' mid-size cruisers.
Production Years:
The VZ800 Marauder was produced from 1997 to 2004.
Manufacturing Location:
Japan
