VZ800.K9-Suppl (ID=2261).pdf

VZ800

USE THIS MANUAL WITH:

VZ800 SERVICE MANUAL (99500-38053-01E)

99501-38090-01E

VZ800K9 (’09-MODEL) 1

VZ800K9 (’09-MODEL)

This manual describes service data, service specifications, FI and servicing procedures which

differ from those of the VZ800K8 (’08-model).

NOTE:

• Any differences between the VZ800K8 (’08-model) and VZ800K9 (’09-model) in specifi-

cations and service data are indicated with an asterisk mark (*).

• Please refer to the VZ800 (’08-model) service manual for details which are not given in

this manual.

CONTENTS

ABBREVIATIONS USED IN THIS MANUAL ..................................................... 3

COUNTRY AND AREA CODES......................................................................... 3

SPECIFICATIONS .............................................................................................. 4

PERIODIC MAINTENANCE SCHEDULE .......................................................... 5

PERIODIC MAINTENANCE CHART ........................................................ 5

MAINTENANCE AND TUNE-UP PROCEDURES ............................................. 6

AIR CLEANER .......................................................................................... 6

SPARK PLUG ........................................................................................... 8

VALVE CLEARANCE ............................................................................... 11

ENGINE OIL AND OIL FILTER................................................................. 14

THROTTLE CABLE PLAY........................................................................ 16

THROTTLE VALVE SYNCHRONIZATION............................................... 16

EVAPORATIVE EMISSON CONTROL SYSTEM (E-33 ONLY) ............... 16

FI SYSTEM DIAGNOSIS .................................................................................... 17

FI SYSTEM WIRING DIAGRAM ............................................................... 17

ECM TERMINAL ....................................................................................... 18

FAIL-SAFE FUNCTION ...................................................................................... 19

DTC TABLE AND DEFECTIVE CONDITION ........................................... 20

DTC TROUBLESHOOTING ...................................................................... 23

THROTTLE BODY.............................................................................................. 38

CONSTRUCTION ...................................................................................... 38

THROTTLE BODY REMOVAL ................................................................. 39

THROTTLE BODY DISASSEMBLY ......................................................... 41

THROTTLE BODY CLEANING................................................................. 44

THROTTLE BODY INSPECTION ............................................................. 44

THROTTLE BODY REASSEMBLY .......................................................... 45

THROTTLE BODY INSTALLATION ......................................................... 49

2 VZ800K9 (’09-MODEL)

VZ800K9 (’09-MODEL)

CONTENTS

STP SENSOR ADJUSTMENT.................................................................. 50

TP SENSOR ADJUSTMENT .................................................................... 51

ISC VALVE REMOVAL ............................................................................ 52

ISC VALVE INSTALLATION .................................................................... 52

ISC VALVE INSPECTION ........................................................................ 52

ISC VALVE PRESET AND OPENING INITIALIZATION.......................... 53

THROTTLE VALVE SYNCHRONIZATION .............................................. 54

IGNITION SYSTEM............................................................................................ 56

INSPECTION ............................................................................................ 56

WIRING HARNESS ROUTING .......................................................................... 59

CABLE ROUTING.............................................................................................. 62

SPEED SENSOR HARNESS ROUTING ........................................................... 64

THROTTLE BODY INSTALLATION.................................................................. 65

IGNITION COIL INSTALLATION....................................................................... 66

ENGINE MOUNTING ......................................................................................... 68

MUFFLER & EXHAUST PIPE INSTALLATION ................................................ 69

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................................. 70

SPECIAL TOOLS............................................................................................... 71

TIGHTENING TORQUE ..................................................................................... 71

ENGINE..................................................................................................... 71

SERVICE DATA................................................................................................. 72

EMISSION CONTROL SYSTEM ....................................................................... 82

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ................ 82

EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33).......... 83

PAIR (AIR SUPPLY) SYSTEM INSPECTION ................................................... 84

HEATED OXYGEN SENSOR (HO2S) INSPECTION

(For E-02, 19, 24, 33)......................................................................................... 84

EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION

(Only for E-33)................................................................................................... 84

EVAP SYSTEM PURGE CONTROL SOLENOID VALVE ....................... 84

FUEL SHUT-OFF VALVE......................................................................... 86

PAIR (AIR SUPPLY) SYSTEM DIAGRAM ........................................................ 87

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................................. 87

EVAP CANISTER HOSE ROUTING (Only for E-33) ........................................ 88

WIRING DIAGRAM ............................................................................................ 89

VZ800K9 (’09-MODEL) 3

ABBREVIATIONS USED IN THIS MANUAL

NOTE:

Please refer to the VZ800K8 (’08-model) service manual for other abbreviations which are not given in this

manual.

I ISC Valve

: Idle Speed Control Valve (ISCV)

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

MODEL

CODE

COUNTRY or AREA

EFFECTIVE FRAME NO.

VZ800

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1B4111200  –

JS1VS56A 92100001 –

JS1B4111100108032 –

JS1B4111300  –

JS1VS56A 92100001 –

VZ800Z

E-02

E-03

E-19

E-24

E-28

E-33

U.K.

U.S.A. (Except for california)

E.U.

Australia

Canada

California (U.S.A.)

JS1B4111200  –

JS1VS56A 92100001 –

JS1B4111100107912 –

JS1B4111300  –

JS1VS56A 92100001 –

VZ800U

E-19

E.U.

JS1B4211100100196 –

VZ800ZU

E-19

E.U.

JS1B4211100100191 –

4 VZ800K9 (’09-MODEL)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................* 2 395 mm (94.3 in)

Overall width ....................................................................................... 920 mm (36.2 in)

Overall height ...................................................................................... 1 125 mm (44.3 in)

Wheelbase .......................................................................................... 1 655 mm (65.2 in)

Ground clearance................................................................................ 140 mm (5.5 in)

Seat height .......................................................................................... 700 mm (27.6 in)

* Curb mass ........................................................................................ 265 kg (584 lbs)

ENGINE

Type..................................................................................................... Four-stroke, liquid-cooled, OHC, 45-degree, V-twin

Number of cylinders ............................................................................ 2

Bore .................................................................................................... 83.0 mm (3.268 in)

Stroke.................................................................................................. 74.4 mm (2.929 in)

Displacement ...................................................................................... 805 cm 3 (49.1 cu. in)

Compression ratio ............................................................................... 9.4 : 1

Fuel system ........................................................................................ Fuel injection

Air cleaner ........................................................................................... Non-woven fabric element

Starter system..................................................................................... Electric

Lubrication system .............................................................................. Wet sump

Idle speed ........................................................................................... 1 100 ± 100 r/min

DRIVE TRAIN

Clutch .................................................................................................. Wet multi-plate type

Transmission ....................................................................................... 5-speed constant mesh

Gearshift pattern ................................................................................. 1-down, 4-up

Primary reduction................................................................................ 1.690 (71/42)

Secondary reduction ratio ................................................................... 1.000 (30/30)

Gear ratios, Low ................................................................................ 2.461 (32/13)

2nd ................................................................................. 1.631 (31/19)

3rd.................................................................................. 1.227 (27/22)

4th .................................................................................. 1.000 (25/25)

Top ................................................................................. 0.814 (22/27)

Final reduction ratio............................................................................. 3.503 (17/15 × 34/11)

Drive system ....................................................................................... Shaft Drive

CHASSIS

Front suspension................................................................................. Inverted telescopic, coil spring, oil damped

Rear suspension ................................................................................. Link type, coil spring, oil damped

Front fork stroke .................................................................................. 140 mm (5.5 in)

Rear wheel travel ................................................................................ 105 mm (4.1 in)

Caster ................................................................................................. 33° 15’

Trail...................................................................................................... 141 mm (5.6 in)

Steering angle..................................................................................... 38° (right & left)

Turning radius ..................................................................................... 3.0 m (9.8 ft)

Front brake .......................................................................................... Disc brake

Rear brake .......................................................................................... Drum brake

Front tire size ...................................................................................... 130/90-16 M/C 67H, tubeless

Rear tire size ....................................................................................... 170/80-15 M/C 77H, tubeless

ELECTRICAL

Ignition type......................................................................................... Electronic ignition (Transistorized)

Ignition timing ......................................................................................* 7° B.T.D.C. at 1 100 r/min

Spark plug........................................................................................... NGK: DPR7EA-9 or DENSO: X22EPR-U9.......... E-03, 28

* NGK: DR7EA or DENSO: X22ESR-U ................. E-02, 19, 24, 33

Battery................................................................................................. 12 V 36.0 kC (10 Ah)/10 HR

Generator ............................................................................................ Three-phase A.C. generator

Main fuse ............................................................................................ 30 A

Fuse ....................................................................................................* 10/10/10/10/10/20 A

Headlight ............................................................................................. 12 V 60/55 W (H4)

Brake light/Taillight .............................................................................. LED

Front turn signal light........................................................................... 12 V 21/5 W .................E-03, 28, 33

12 V 21 W ....................Others

Rear turn signal light ........................................................................... 12 V 21 W

Position/parking light ........................................................................... 12 V 5 W ......................E-02,19

License plate light ............................................................................... 12 V 5 W

Speedometer light ............................................................................... LED

High beam indicator light .................................................................... LED

Turn signal indicator light .................................................................... LED

Neutral indicator light .......................................................................... LED

Coolant temperature/Oil pressure warning light.................................. LED

FI warning light.................................................................................... LED

CAPACITIES

Fuel tank, including reserve .............................................................. 15.0 L (4.0/3.3 US/Imp gal).................... E-33

15.5 L (4.1/3.4 US/Imp gal).................... Others

reserve.............................................................................. 3.0 L (0.8/0.7 US/Imp gal)

Engine oil, oil change ........................................................................ 3 000 ml (3.2/2.6 US/Imp qt)

with filter change ............................................................. 3 400 ml (3.6/3.0 US/Imp qt)

Overhaul .......................................................................... 3 700 ml (3.9/3.3 US/Imp qt)

Final gear oil ....................................................................................... 200 – 220 ml (6.8/7.0 – 7.4/7.7 US/Imp oz)

Coolant................................................................................................ 1.5 L (1.6/1.3 US/Imp qt)

These specifications are subject to change without notice.

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