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Suzuki VS700 Service Manual

Summary of VS700

  • Page 1

    Vs700/750/800 service manual *99500-38062-03e* * 9 9 5 0 0 - 3 8 0 6 3 - 0 3 e * 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 *99500-38062-03e* vs700/750/800 ser vic e m an ua l 534 1.0625 f g h j k l m n p r s t v w x y k1 k2 k3 k4 k5 k6 k7.

  • Page 2: Important

    Prepared by printed in u.S.A. Part no. 99500-38062-03e 534 1990 important all street-legal suzuki motorcycles with engine displacement of 50 cc or greater are subject to environmental protection agency emission regulations. These regulations set specific standards for exhaust emission output levels ...

  • Page 5: Group Index

    Group index general information periodic maintenance and tune-up procedures engine shaft drive cooling system fuel and lubrication system electrical system 1 2 3 4 5 6 7 chassis servicing information 8 9 10 emission control informations.

  • Page 6: Supplements

    23 24 25 vs700gle vs700glh (’87-model) vs750glj (’88-model) vs750glk (’89-model) vs750glfl/glpl (’90-model) vs750glfm/glpm (’91-model) 11 12 13 14 15 vs800gln (’92-model) vs800glp/r (’93/’94-model) vs800gls (’95-model) vs800glt/v (’96/’97-model) 16 17 18 19 vs800glw/x (’98/’99-model) vs800gly/k1/k2/...

  • Page 273: Vs700Gle

    11 vs700gle.

  • Page 294: Vs700Glh ('87-Model)

    Vs700glh ('87-model) 12.

  • Page 318: Vs750Glj ('88-Model)

    Vs750glj ('88-model) 13.

  • Page 344: Vs750Glk ('89-Model)

    Vs750glk ('89-model) 14.

  • Page 353

    15.

  • Page 363: Vs800Gln ('92-Model)

    Vs800gln ('92-model) 16.

  • Page 394: Vs800Glp/r ('93/94-Model)

    Vs800glp/r ('93/94-model) 17.

  • Page 406: Vs800Gls ('95-Model)

    Vs800gls ('95-model) 18.

  • Page 422: Vs800Glt/v ('96/'97-Model)

    Vs800glt/v ('96/'97-model) 19.

  • Page 443: Vs800Glw/x ('98/'99-Model)

    Vs800glw/x ('98/'99-model) 20

  • Page 456

    21 this section describes service data and service specifications which differ from those of the vs800glx (‘99-model). Contents specifications.............................................................................. 21- 1 service data ...............................................................

  • Page 457: Specifications

    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 ................................................................................. *...

  • Page 458: Service Data

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-2 service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) ——— ex. 26 (1.02) ——— valve lift in. 8.5 (0.33) ——— ex. 8.5 (0.33) ——— valve clearance in. & ex. 0.08 – 0.13 (when cold) (0.003 – 0.005) ——— valve guide to valve stem...

  • 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...

  • Page 460

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-4 item standard limit piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) ——— 2nd 1.21 – 1.23 (0.0476 – 0.0484) ——— oil 2.51 – 2.53 (0.0988-0.0996) ——— piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) ——— 2nd 1.170 – 1.190 (0.0461 – 0.0469...

  • Page 461

    21-5 vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) clutch unit: mm (in) item standard limit drive plate thickness no.1 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) no.2 3.45 – 3.55 3.15 (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 drive side 0.03 – 0.064 (0.001 – 0.025) ——— carburetor item specification e-02, 04, 25, 34 carburetor type mikuni bs36s...

  • Page 463

    21-7 vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) carburetor item specification 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 ± 0.04 in) (0.36 ± 0.04 in) main jet (m.J.) #10...

  • Page 464

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-8 carburetor item specification 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 ± 0.04 in) (0.36 ± 0.04 in) main jet (m.J.) #1...

  • Page 465

    21-9 vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) carburetor item specification 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 ± 0.04 in) (0.36 ± 0.04 in) main jet (m....

  • Page 466

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-10 wattage unit: w item specification e-02 e-03, 28, 33 the others headlight hi 60 ← ← lo 55 ← ← parking light 3.4 4 brake light/taillight 21/5 ← ← turn signal light 21 21/5 (front), 21 (rear) 21 speedometer light 3.4 ← ← water temp. Meter light 1.7 ← ← t...

  • 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 ——— 1.6 (0.06) rear ——— 2.0 (0.08) suspension unit: mm (in) item standard limit note front fork stroke 130 (5.12) ——— front fork spring free le...

  • Page 468

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-12 fuel + oil + coolant item specification note fuel type u.S.A. And canada other models fuel tank including reserve 11.0 l california (2.9/2.4 us/lmp gal) model only 12.0 l (3.2/2.6 us/lmp gal) other models reserve 3.0 l (0.8/0.7 us/lmp gal) engine oil t...

  • Page 469: Steering Stem

    21-13 vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) steering stem construction handlebar holder 15 – 25 n.M 1.5 – 2.5 kgf.M ( 11.0 – 18.0 lb-ft ) 15 – 25 n.M 1.5 – 2.5 kgf.M ( 11.0 – 18.0 lb-ft ) 40 – 50 n.M 4.0 – 5.0 kgf.M ( 29.0 – 36.0 lb-ft ) 40 – 50 n.M 4.0 – 5.0 kgf.M ( 29.0 – 36.0 lb-ft ) 80 – 100...

  • Page 470: Cable Routing

    Vs800gly/k1/k2/k3 (’00/’01/’02/’03-model) 21-14 cable routing clamp wiring harness wiring harness.

  • Page 471: Vs800Glk4 (’04-Model)

    22 vs800glk4 (’04-model) vs800glk4 (’04-model) 22-1 contents 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. Spec...

  • Page 472: Specifications

    22-2 vs800glk4 (’04-model) specifications dimensions and dry mass overall length ...................................................................................... 2 250 mm (88.6 in) overall width ....................................................................................... 885 mm (34....

  • Page 473: Service Data

    Vs800glk4 (’04-model) 22-3 service data valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve lift in. 8.5 (0.33) — ex. 8.5 (0.33) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to v...

  • Page 474

    22-4 vs800glk4 (’04-model) cylinder + piston + piston ring unit: mm (in) item standard limit camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0060) camshaft journal holder i.D. No. 1 left side no. 2 right side 20.012 – 20.025 (0.7879 – 0.7884) — no. 1 right side no. 2 left sid...

  • Page 475

    Vs800glk4 (’04-model) 22-5 conrod + crankshaft unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190...

  • Page 476

    22-6 vs800glk4 (’04-model) clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.45 – 3.55 (0.136 – 0.140) 3.15 (0.124) drive plate claw width 15.8 – 16.0 (0.622 – 0.630) 15.0 (0.591) driven plate...

  • Page 477

    Vs800glk4 (’04-model) 22-7 shaft drive unit: mm (in) carburetor carburetor item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.64 (0.001 – 0.025) — item specification e-03 carburetor type mikuni bs36ss (no. 1) mikuni bds36ss (...

  • Page 478

    22-8 vs800glk4 (’04-model) carburetor electrical unit: mm (in) item specification 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 (1.09 ± 0.04 in) 9.1 ± 1.0 mm (0.36 ± 0.04 in) main jet (m.J....

  • Page 479

    Vs800glk4 (’04-model) 22-9 wattage unit: w brake + wheel unit: mm (in) item specification headlight hi 60 lo 55 parking light 3.4 brake light/taillight 21/5 turn signal light 21/5 (front), 21 (rear) speedometer light 3.4 water temp. Meter light 1.7 turn signal indicator light 3 high beam indicator l...

  • Page 480

    22-10 vs800glk4 (’04-model) suspension unit: mm (in) tire pressure 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 — 1.6 (0.06) rear — 2.0 (0.08) item standard limit note front fork stroke 130 (5.12) — front fork spr...

  • Page 481

    Vs800glk4 (’04-model) 22-11 fuel + oil + coolant thermostat + radiator + fan 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% ...

  • Page 482: Wiring Diagram

    22-12 vs800glk4 (’04-model) wiring diagram off on on off off on off on n w p t b on p off 1 2 3 4 5 +- 12v on off o/g lg b w y bl/w o/g g/y b/br o/g lg b w y bl/w o/g g/y b/br b/w b/w r/w o o/g br r/w o o/g br r o gr br r o gr br bl/w bl g bl/w bl g o/w w o/w w b/y o/w b/y o/w o/g w/b o/g w/b lg b/w...

  • Page 483: Vs800K5 ('05-Model)

    23 vs800k5 ('05-model) contents page specifications.................................................................................... 23- 2 service data....................................................................................... 23- 3 wiring harness routing.................................

  • Page 484: Specifications

    – 2 – specifications dimensions and dry mass overall length ...................................................................................... 2 250 mm (88.6 in) overall width........................................................................................* 765 mm (30.1 in) overall height...

  • Page 485: Service Data

    – 3 – service data valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve lift in. 8.5 (0.33) — ex. 8.5 (0.33) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clearance i...

  • Page 486

    – 4 – cylinder + piston + piston ring unit: mm (in) item standard limit camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0060) camshaft journal holder i.D. No. 1 left side no. 2 right side 20.012 – 20.025 (0.7879 – 0.7884) — no. 1 right side no. 2 left side 25.012 – 25.025 (0....

  • Page 487

    – 5 – conrod + crankshaft unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 0.970 – 0.990 (0.0382 – 0.0390) — 2nd 1.170 – 1.190 (0.0461 – 0.0469) — ...

  • Page 488

    – 6 – clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.45 – 3.55 (0.136 – 0.140) 3.15 (0.124) drive plate claw width 15.8 – 16.0 (0.622 – 0.630) 15.0 (0.591) driven plate distortion — 0.10 (0...

  • Page 489

    – 7 – shaft drive unit: mm (in) carburetor carburetor item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.64 (0.001 – 0.025) — item specification e-03, 28 carburetor type mikuni bs36ss (no. 1) mikuni bds36ss (no. 2) bore size ...

  • Page 490

    – 8 – electrical unit: mm (in) item specification note firing order 1·2 spark plug type n.G.K.: dpr8ea-9 n.D.: x24epr-u9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) at 1 atm. Signal coil resistance approx. 50 – 200 Ω (g – bl) ignition coil resistance primary * 1.8 – 2.6 Ω + tap – - ...

  • Page 491

    – 9 – wattage unit: w brake + wheel unit: mm (in) item specification headlight hi 60 lo 55 parking light 3.4 brake light/taillight 21/5 turn signal light 21/5 (front), 21 (rear) speedometer light 3.4 water temp. Meter light 1.7 turn signal indicator light 3 high beam indicator light 1.7 neutral indi...

  • Page 492

    – 10 – suspension unit: mm (in) tire pressure 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 — 1.6 (0.06) rear — 2.0 (0.08) item standard limit note front fork stroke 130 (5.12) — front fork spring free length 363.3...

  • Page 493

    – 11 – fuel + oil + coolant thermostat + radiator + fan 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...

  • Page 494: Wiring Harness Routing

    – 12 – wiring harness routing clamp clamp clamp tail/brake light wiring harness tail/brake light ignition coil lead wire rear turn signal light (r & l) battery - lead wire license plate light clamp wiring harness high-tension cord ignitor to rear turn signal light (r) to rear turn signal light (l) s...

  • Page 495: Clutch Hose Routing

    – 13 – clutch hose routing set the end-fitting hex 17 part to set the end of the fuel tank bracket. Parallel with the handle stay. Clutch hose carbureter handle stay 28˚ through the brake hose into the hole of the upper bracket. Cushion clutch hose.

  • Page 496: Front Brake Hose Routing

    – 14 – front brake hose routing handle balancer installation tool holder installation 21˚ parallel with handle stay. 1 mm 35.5 mm.

  • Page 497

    – 15 – evaporative emission control system (for e-33) rear fender canister cover white paint is upward. Clip end is forward. Red paint is putside. Red paint (surge side) clip end is backward. White paint is outside. Clip end is downward..

  • Page 498: Wiring Diagram

    – 16 – wiring diagram off on on off off on off on n w p t b on p off 1 2 3 4 5 +- 12v on off o/g o/g lg lg b w y bl/w bl/w o/g o/g g/y g/y b/br b/br o/g lg b w y bl/w o/g g/y b/br b/w b/w b/w r/w r/w o o/g o/g br br r/w o o/g br r o gr gr br br r o gr br bl/w bl/w bl bl g bl/w bl g o/w o/w w o/w w b...

  • Page 499: Vs800K6 ('06-Model)

    24 vs800k6 ('06-model) contents page specifications.................................................................................... 24- 2 service data....................................................................................... 24- 3 regulator/rectifier....................................

  • Page 500: Specifications

    – 2 – specifications dimensions and dry mass overall length ........................................................................... 2 250 mm (88.6 in) overall width............................................................................. 765 mm (30.1 in) overall height .........................

  • Page 501: Service Data

    – 3 – service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve lift in. 8.5 (0.33) — ex. 8.5 (0.33) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) — ...

  • Page 502

    – 4 – camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 35.954 – 35.994 (1.4155 – 1.4171) 35.660 (1.4039) ex. 36.919 – 36.959 (1.4535 – 1.4551) 36.620 (1.4417) camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (...

  • Page 503

    – 5 – conrod + crankshaft unit: mm (in) oil pump item standard limit piston ring to groove clearance 1st — 0.180 (0.007) 2nd — 0.150 (0.006) piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st ...

  • Page 504

    – 6 – clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.45 – 3.55 (0.136 – 0.140) 3.15 (0.124) drive plate claw width 15.8 – 16.0 (0.622 – 0.630) 15.0 (0.591) driven plate distortion — 0.10 (0...

  • Page 505

    – 7 – shaft drive unit: mm (in) carburetor carburetor item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.64 (0.001 – 0.025) — item specification e-03, 28 carburetor type mikuni bs36ss (no. 1) mikuni bds36ss (no. 2) bore size ...

  • Page 506

    – 8 – thermostat + radiator + fan electrical unit: mm (in) item standard limit thermostat valve opening tempera- ture 75.0 ± 1.5 °c (167 ± 2.7 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — radiator cap valve release pres- sure 110 ± 15 kpa (1.1 ± 0.15 kgf/cm 2 , 15.6 ± 2.1 psi)...

  • Page 507

    – 9 – wattage unit: w brake + wheel unit: mm (in) item specification headlight hi 60 lo 55 parking light 3.4 brake light/taillight 21/5 turn signal light 21/5 (front), 21 (rear) speedometer light 3 water temp. Meter light 1.7 turn signal indicator light 3 high beam indicator light 1.7 neutral indica...

  • Page 508

    – 10 – suspension unit: mm (in) tire pressure item standard limit tire size front 100/90-19m/c 57h — rear 140/90-15m/c 70h — tire tread depth front — 1.6 (0.06) rear — 2.0 (0.08) item standard limit note front fork stroke 130 (5.12) — front fork spring free length 363.3 (14.3) 356 (14.0) front fork ...

  • Page 509

    – 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 ether), less than 10% ethanol, or less than 5% methanol with appropriat...

  • Page 510: Regulator/rectifier

    – 12 – 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 test...

  • Page 511: Wiring Diagram

    – 13 – wiring diagram off on on off off on off on n w p t b on p off 1 2 3 4 5 +- 12v on off o/g o/g lg lg b w y bl/w bl/w o/g o/g g/y g/y b/br b/br o/g lg b w y bl/w o/g g/y b/br b/w b/w b/w r/w r/w o o/g o/g br br r/w o o/g br r o gr gr br br r o gr br bl/w bl/w bl bl g bl/w bl g o/w o/w w o/w w b...

  • Page 512: Vs800K7 ('07-Model)

    Contents pag e specifications.................................................................................... 25-2 service data........................................................................................ 25-3 25 vs800k7 ('07-model) vs800k7 ('07-model) 25-1 this chapter describes serv...

  • Page 513: Specifications

    – 2 – specifications dimensions and dry mass overall length ........................................................................... 2 250 mm (88.6 in) overall width............................................................................. 765 mm (30.1 in) overall height .........................

  • Page 514: Service Data

    – 3 – service data valve + guide unit: mm (in) item standard limit valve diam. In. 30 (1.18) — ex. 26 (1.02) — valve lift in. 8.5 (0.33) — ex. 8.5 (0.33) — valve clearance (when cold) in. & ex. 0.08 – 0.13 (0.003 – 0.005) — valve guide to valve stem clear- ance in. 0.010 – 0.037 (0.0004 – 0.0015) — ...

  • Page 515

    – 4 – camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 35.954 – 35.994 (1.4155 – 1.4171) 35.660 (1.4039) ex. 36.919 – 36.959 (1.4535 – 1.4551) 36.620 (1.4417) camshaft journal oil clearance 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (...

  • Page 516

    – 5 – conrod + crankshaft unit: mm (in) oil pump item standard limit piston ring to groove clearance 1st — 0.180 (0.007) 2nd — 0.150 (0.006) piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.21 – 1.23 (0.0476 – 0.0484) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st ...

  • Page 517

    – 6 – clutch unit: mm (in) transmission unit: mm (in) except ratio item standard limit drive plate thickness no. 1 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) no. 2 3.45 – 3.55 (0.136 – 0.140) 3.15 (0.124) drive plate claw width 15.8 – 16.0 (0.622 – 0.630) 15.0 (0.591) driven plate distortion — 0.10 (0...

  • Page 518

    – 7 – shaft drive unit: mm (in) carburetor carburetor item standard limit secondary bevel gear backlash 0.05 – 0.32 (0.002 – 0.013) — final bevel gear backlash drive side 0.03 – 0.64 (0.001 – 0.025) — item specification e-03, 28 carburetor type mikuni bs36ss (no. 1) mikuni bds36ss (no. 2) bore size ...

  • Page 519

    – 8 – thermostat + radiator + fan electrical unit: mm (in) item standard limit thermostat valve opening tempera- ture 75.0 ± 1.5 °c (167 ± 2.7 °f) — thermostat valve lift over 6 mm (0.24 in) at 90 °c (194 °f) — radiator cap valve release pres- sure 110 ± 15 kpa (1.1 ± 0.15 kgf/cm 2 , 15.6 ± 2.1 psi)...

  • Page 520

    – 9 – wattage unit: w brake + wheel unit: mm (in) item specification headlight hi 60 lo 55 parking light 3.4 brake light/taillight 21/5 turn signal light 21/5 (front), 21 (rear) speedometer light 3 water temp. Meter light 1.7 turn signal indicator light 3 high beam indicator light 1.7 neutral indica...

  • Page 521

    – 10 – suspension unit: mm (in) tire pressure item standard limit tire size front 100/90-19m/c 57h — rear 140/90-15m/c 70h — tire tread depth front — 1.6 (0.06) rear — 2.0 (0.08) item standard limit note front fork stroke 130 (5.12) — front fork spring free length 363.3 (14.3) 356 (14.0) front fork ...

  • Page 522

    – 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 ether), less than 10% ethanol, or less than 5% methanol with appropriat...

  • Page 523: Important

    Important all street-legal suzuki motorcycles with engine displacement of 50 cc or greater are subject to environmental protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includ...

  • Page 524: Important

    Important all street-legal suzuki motorcycles with engine displacement of 50 cc or greater are subject to environmental protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includ...

  • Page 525: Important

    Prepared by printed in u.S.A. Part no. 99500-38062-03e 534 1990 important all street-legal suzuki motorcycles with engine displacement of 50 cc or greater are subject to environmental protection agency emission regulations. These regulations set specific standards for exhaust emission output levels ...

  • Page 526: Vs700/750/800

    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 vs700/750/800 service manual *99500-38063-03e* * 9 9 5 0 0 - 3 8 0 6 3 - 0 3 e * *99500-38063-03e* vs700/750/800 ser vic e m an ua l 536.P 1.0625 f g h j k l m n p r s t v w x y k 1 k 2 k 3 k4 k 5 k 6 k 7 k 8.