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Haynes Suzuki repair manuals cover your specific vehicle with easy to follow pictures and text, save thousands on maintaining your vehicle.
Earn $5 for Each $100 You Spend on eligible products - up to a maximum of $30 ZillaCash per order for orders totaling $600 or more. Any ZillaCash you earn is automatically applied to the next purchase, so you can sit back, enjoy the ride and feel the savings blow through your hair. Fitment Notes Universal Fit Parts fit a range of vehicles, and may or may not fit your current bike without modification. Exact Fit Parts are designed specifically for your 2003 Suzuki VZ800 Marauder.
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. The section titles are listed in the GROUP INDEX. Holding the manual as shown at the right will allow you to find the first page of the section easily. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view.
Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40. If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart. BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil. GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze.
Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Incoming search terms:. Cover the throttle bodies to prevent anything from dropping into the engine.
Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve.
(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7.
Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve.
(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.
(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.
Incoming search terms:. The author of this manual has the conviction that the only way in which a meaningful and easy to follow text can be written is first to do the work himself, under conditions similar to those found in the average household. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner.
Unless specially mentioned, and therefore considered essential, Honda service tools have not been used. There is invariably some alternative means of slackening or removing some vital component when service tools are not available and isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs. In consequence, cross reference throughout this manual is both straightforward and logical.
When a reference is made ‘See Section 5.12′ it means Section 5, paragraph 12 in the same Chapter. If another Chapter were meant, the text would read ‘See Chapter 2, Section 5.12′. All photographs are captioned with a Section/paragraph number to which they refer and are always relevant to the Chapter text adjacent.
Figure numbers (usually line illustrations) appear in numerical order, within a given Chapter. 1.1 therefore refers o the first figure in Chapter 1. Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity. We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us.
No liability can be ccepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information give Incoming search terms:. In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later.
Front wheel removal: Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution: there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia. Goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine.
Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal Incoming search terms:. REMOVING THE STOCK EXHAUST SYSTEM 1.
Loosenthe right hand side footrest assembly. Loosenthe two head pipes at the cylinder head. Loosen the muffler clamps, located on the inlet end of the mufflers. Remove the two nuts that mount the lower muffler to motorcycle. Keep the two mufflers bolted together as an assembly. Lift the muffler assembly up to clear the studs from the mounting holes.
Pull the mufflers off the head pipes and set them aside. Remove the two flanged steel spacers from the hole in the rubber cushions, where the stock muffler assembly mounted. Reinstall the steel spacers through the backside of the rubber cushions so the flanged end of the spacers are on the backside of the cushions, opposite of there original position. Remove the rear most heat shields from both of the head pipes and set them aside. Remove the stock exhaust gaskets from the ends of both pipes.
The Vance & Hines slip-on does not use a gasket at the slip joint. Install the new muffler mounting bracket (stamped with the # 233 ) to the front side of the two holes with the rubber cushions the two of the 5/16″x 1 1/4″ bolt and two 5/16″ lock nuts (hardware supplied) through the two holes in the bracket that are spaced farthest apart. When mounted correctly, the bracket should bend up and out from the motorcycle Incoming search terms:.
Step 1: Identify the key components that complete our Superbike kit: You should have 2 lines (front kit), 1 double banjo bolt and 2 lower adapters. There are also a total of 7 washers. 5 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines; all other installations VOID warranty. Inspect your brake system after every race. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip!
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Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. (See picture S4) Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt (see picture S5) is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, straight banjo (from right line), washer, 12-degree banjo (from left line), washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds.
( See picture S6) Make sure that the 90-degree fittings on each caliper are pointing away from the bike just a little bit (see pictures S7 through S9 of calipers). Thread each banjo end into the adapter, and torque to 6 ½ Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, we recommend using a zip-tie to bring the lines together about an inch above the lower triple clamp area.
(Picture S10) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with DOT 4-brake fluid is recommended. Incoming search terms:. Always make a pre-ride inspection before you start the engine. You may prevent an accident or equipment damage.
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2 Many accidents involve inexperienced riders. Most countries require a special riding test or license. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. 3 Many car/motorcycle accidents happen because the car driver does not “ see the motorcyclist.
Make yourself conspicuous to help avoid the accident that is not your fault:. Wear bright or reflective clothing. Don’t drive in another motorist’s “blind spot” 4 Obey all national, and local laws and regulations Excessive speed is a factor in many accidents. Obey the speed limits am NEVER travel faster than conditions warrant. Signal before you make a turn or lane change. Your size and manoeuvrability can surprise other motorists.5 Don’t let other motorists surprise you.
Use extra caution at intersections, parking entrances and exits and driveways. 6 Keep both hands on the handlebars and both feet on the footrests while riding. A passenger should hold onto the motorcycle or the rider with both hands, and keep both feet on the passenger footrests. PROTECTIVE APPAREL 1 Most motorcycle accidents fatalities are due to head impact. ALWAYS wear a helmet.
You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection. The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs.
2000 Suzuki Vz800 Service Manual
3 Do not wear loose clothing which could catch on the control levers, footrests, or wheels.