Suzuki Marauder VZ800 2001 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Marauder Year: 2001 Model Code: VZ800 Product Name: Suzuki Marauder VZ800 2001 Factory Service Repair Manual 👋 Introduction Market Position Market Segment: Cruiser...

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类型: Motorcycle

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标签: 2001 Marauder Models Marauder VZ800 Motorcycle Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Marauder

Year:

Model Code:

VZ800

Product Name:

Suzuki Marauder VZ800 2001 Factory Service Repair Manual

👋 Introduction

Market Position

Market Segment:

Cruiser Motorcycle

Target Audience:

Suzuki Marauder VZ800 owners, independent motorcycle mechanics, DIY enthusiasts

Competitive Analysis

Competitors:

Honda Shadow series, Yamaha Virago/V-Star series, Kawasaki Vulcan series, Harley-Davidson Sportster series

Key Features

Manual Benefit 1:

Authoritative and accurate information directly from Suzuki factory sources

Manual Benefit 2:

Saves money by enabling DIY repairs and maintenance

Manual Benefit 3:

Ensures proper maintenance for longevity and optimal performance

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair for Suzuki Marauder VZ800 (2001 model year)

Page Count

Estimated Pages:

400-600

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, and repair of the 805cc V-twin engine

Fuel System:

Carburetor tuning, cleaning, overhaul, fuel pump, fuel tank, lines

Ignition System:

Spark plug service, ignition timing, coil inspection, CDI unit

Transmission:

Clutch operation, gearbox disassembly and assembly, shift mechanism

Drivetrain:

Shaft drive system, rear differential maintenance

Suspension:

Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake fluid bleeding, pad replacement

Electrical System:

Wiring diagrams, lighting system, battery, charging system, starter motor, fuses, relays

Cooling System:

Liquid-cooled engine cooling system, radiator, water pump, thermostat

Exhaust System:

Muffler, exhaust pipes, mounting

Chassis And Frame:

Frame inspection, steering head bearing service

Bodywork:

Panel removal and installation, seat, fenders, fuel tank mounting

Procedures Included

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain adjustment (if applicable), lubrication points

Troubleshooting:

Diagnostic charts for common problems, fault finding for engine, electrical, and mechanical issues

Repair:

Step-by-step instructions for component repair and replacement

Disassembly Assembly:

Complete breakdown and reassembly of major components and sub-assemblies

Adjustment:

Carburetor synchronization, idle speed adjustment, brake lever free play, clutch cable adjustment

Wiring Diagrams:

Comprehensive electrical system schematics with component identification

Technical Depth

Depth:

Comprehensive, covering everything from basic user maintenance to complete engine rebuilds and electrical diagnostics

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for workshop use

Print Quality

Image Resolution:

High resolution for clear diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, V-twin, SOHC, 4 valves per cylinder

Displacement:

805 cc (49.1 cu. in.)

Bore X Stroke:

83.0 mm x 74.4 mm (3.27 in. x 2.93 in.)

Compression Ratio:

9.3:1

Performance

Horsepower:

Approx. 50 HP (37 kW) @ 6000 RPM (Estimates may vary)

Torque:

Approx. 66 Nm (48.7 lb-ft) @ 4000 RPM (Estimates may vary)

Fuel System

Carburetion:

Two Mikuni B26 carburetors

Fuel Tank Capacity:

17.0 L (4.5 US gal)

Recommended Fuel:

Unleaded gasoline, Octane Rating 87 or higher

Ignition System

Ignition Type:

Electronic ignition (CDI)

Spark Plugs:

NGK CR9E / DENSO U27ETR (or equivalent)

Cooling System

Cooling Medium:

Liquid Cooling

Coolant Capacity:

Approx. 1.9 L (2.0 US qt)

Lubrication System

Oil Type:

SAE 10W-40, API SG or SH or SJ

Oil Capacity With Filter:

Approx. 3.2 L (3.4 US qt)

Oil Filter Part Number:

Suzuki P/N: 16510-05240 (or equivalent aftermarket)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

Shaft Drive

Transmission Oil Type:

Gear Oil SAE 80W-90 API GL-5

Transmission Oil Capacity:

Approx. 1.1 L (1.2 US qt)

📐 Dimensions

Exterior

Overall Length:

2375 mm (93.5 in.)

Overall Width:

830 mm (32.7 in.)

Overall Height:

1160 mm (45.7 in.)

Wheelbase:

1660 mm (65.4 in.)

Ground Clearance:

140 mm (5.5 in.)

Weights

Dry Weight:

223 kg (492 lbs)

Wet Weight:

Approx. 240 kg (529 lbs) (with all fluids)

Load Capacity:

Approx. 180 kg (397 lbs) (Rider + Luggage)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle specific ratings not applicable in standard automotive format)

Active Features

Braking System:

Dual hydraulic disc front, single hydraulic disc rear

Front Brake Spec:

2-piston caliper, 310 mm disc

Rear Brake Spec:

1-piston caliper, 270 mm disc

Passive Features

Lighting:

Halogen headlight, LED tail light, incandescent turn signals

Mirrors:

Dual rear-view mirrors

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle electronics)

Driver Assistance

Assistance Features:

N/A (No advanced rider assistance systems)

Connectivity

Connectivity Features:

N/A (No modern connectivity features)

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first.

Oil Filter Change Interval:

Every 8,000 km (5,000 miles) or 12 months, with engine oil change.

Spark Plug Inspection Interval:

Every 4,000 km (2,500 miles)

Clutch Cable Adjustment Interval:

Every 4,000 km (2,500 miles)

Fork Oil Change Interval:

Recommended every 10,000 - 15,000 km (6,000 - 9,000 miles)

Fluid Specifications

Engine Oil Viscosity:

10W-40

Brake Fluid Type:

DOT 4

Coolant Type:

Suzuki Super Long Life Coolant or equivalent (50/50 mixture with distilled water)

Known Issues

Common Issue 1:

Carburetor synchronization drift leading to rough idle or uneven running.

Common Issue 2:

Wear on the steering head bearings, causing notchiness or looseness in steering.

Common Issue 3:

Potential for oil leaks from the engine case gaskets or seals over time.

Common Issue 4:

Front fork seal leaks, requiring replacement of seals and oil.

Common Issue 5:

Exhaust pipe corrosion, particularly in areas with harsh weather conditions.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki, a Japanese multinational corporation, is renowned for its wide range of motorcycles, automobiles, marine engines, and more.

Model Evolution

Vz800 Lineage:

The Marauder VZ800 (also known as the Intruder 800 in some markets) is part of Suzuki's long-standing cruiser motorcycle lineage, evolving from earlier Intruder models.

Production

Production Period:

The VZ800 Marauder was produced from 1997 to 2004.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2001 VZ800 are not widely documented, Suzuki motorcycles have consistently received positive reviews for reliability and performance in their class.