1990–1993 Suzuki VX800 Workshop Repair Manual
Complete technical service resource for VX800L/M/N/P models. Covers engine, transmission, chassis, electrical systems and suspension maintenance procedures with specifications and torque values.
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Models Covered & Key Technical Specifications
Suzuki VX800 (Models L, M, N, P) — 1990–1993
Engineering Analytical Registry | VX800 Series Record.
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Calibrated Engine Displacement: The piston displacement represents 805 cm³ (49.12 cu in) measured as the total cylinder volume capacity Topology.
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Rated Compression Ratio: For optimal combustion performance, 10.0:1 is established at the cylinder head chamber Standards.
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Critical Valve Clearance: The intake and exhaust valve clearance is set to 0.08–0.13 mm (0.003–0.005 in) when cold Matrix.
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Universal Fuel Tank Capacity: The fuel tank requires 18.0 L (4.8/4.0 US/Imp gal) including reserve margin for standard operation Parameters.
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Core Engine Oil Capacity: For standard engine overhaul, the system requires 3300 ml (3.5/2.9 US/Imp qt) of SAE 10W/40 motor oil Bounds.
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Standard Final Gear Oil Specification: The shaft drive final bevel gear case is configured at 200–220 ml (6.8/7.0–7.4/7.7 US/Imp oz) hypoid gear oil Protocol.
Professional Workshop Service Manual & Technical Specifications
Systematic Technical Manual: Motorcycle Suzuki VX800 (Models L, M, N, P) 1990–1993 Workshop Repair Manual System-Standards
Calibration-Scope: VX800L ('90), M ('91), N ('92), P ('93) // Engine-Type: 805cc V-twin Four-stroke OHC TSCC Water-cooled // Year-Coverage: 1990–1993 Multi-model Coverage.
| Assessment-Element | Parameters | Logic |
|---|---|---|
| Engine Systems | Compression testing, valve clearance, ignition timing, fuel delivery | Complete specifications provided |
| Transmission & Drive | 5-speed constant mesh, shaft drive, secondary/final bevel gears | Service procedures documented |
| Brake & Suspension | Hydraulic disc brakes (front/rear), telescopic/swingarm suspension | Component service included |
| Electrical Systems | Fully transistorized ignition, AC generator, battery charging circuit | Troubleshooting reference available |
The repository is divided into general information and specifications, periodic maintenance procedures covering engine tuning and component servicing, engine disassembly and reassembly with inspection documentation, transmission and shaft drive systems with backlash adjustment data, fuel system and carburetor specification tables, cooling system component procedures, complete electrical system diagnostics, chassis service including brakes and suspension, and supplementary troubleshooting logic organized by symptom categories.
Calibration requirements are specified for valve clearance maintenance, with cold-state measurements provided for intake and exhaust positioning. Electrical system documentation covers the fully transistorized ignition arrangement, signal generator coil resistance data, AC generator no-load performance parameters, and regulator/rectifier function across multiple market specifications. Suspension service documentation covers front fork disassembly procedures, rear shock absorber adjustment tables with spring preload and damping force settings, and steering stem bearing adjustment methodology for proper mechanical operation.
Disassembly instructions are documented for the engine's complex module architecture, including crankcase separation using specialized tools, cam chain tensioner operation, and precision bearing removal techniques. Wear limits are specified for piston rings, connecting rod clearances, crankshaft journals, and valve guide dimensions, with service limit values established to determine component replacement requirements.
The document includes torque specifications for engine fasteners to ensure proper bolt and fastener security, with dual-specification tables referencing both conventional and "T"-marked bolts across multiple size categories. Factory procedures are documented for carburetor balancing between front and rear units using vacuum measurement equipment, establishing pilot screw adjustment protocols and idle speed synchronization across the dual-carburetor assembly.
Note: This manual documents torque specifications for engine, transmission, and chassis fasteners to ensure proper mechanical assembly and component integrity throughout the motorcycle's service lifecycle.
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