Brand: SUZUKI
Category: Motorcycle
Manual Type:
Language:
Manual for VL800 - Troubleshooting and error codes + PDF Download
Uploaded: April 8, 2025, 1:42 p.m.
Manual Publish Date: 2007-09-01
Warranty Summary
None
This SUZUKI VL800 Service Manual provides comprehensive instructions for maintenance and repair. It includes a detailed table of contents for easy navigation, covering general information, periodic maintenance schedules, engine service procedures, shaft drive maintenance, fuel and lubrication system servicing, cooling system maintenance, chassis and electrical system repairs, and emission control information. The manual utilizes exploded views and symbols to clarify component parts and work procedures. It emphasizes safety precautions and proper use of tools for effective and safe motorcycle servicing.
Troubleshooting and error codes
| Complaint | Symptom and possible causes | Remedy |
|---|---|---|
| Engine will not start or is hard to start. | Compression too low 1. Worn cylinder. 2. Worn piston ring. 3. Worn valve guide or improper valve seating. 4. Loose spark plug. 5. Broken, cracked, or damaged piston. 6. Slow cranking starter motor. 7. Mistimed valves. 8. Valve clearance out of adjustment. |
Replace. Replace. Repair or replace. Tighten. Replace See electrical section. Adjust. Adjus |
| Spark plug not sparking | 1. Damaged spark plug. 2. Damaged spark plug cap. 3. Fouled spark plug. 4. Wet spark plug. 5. Defective ignition coil. 6. Open or short in high-tension cord. 7. Defective pick-up coil or ignitor unit. |
Replace. Replace. Clean or replace. Clean and dry or replace. Replace. Replace. Replace. |
| No fuel reaching the carburetor | 1. Clogged hole in the fuel tank cap. 2. Defective fuel pump. 3. Clogged or defective fuel valve 4. Defective carburetor needle valve. 5. Clogged fuel hose. 6. Clogged fuel filter. |
Clean or replace. Replace. Clean or replace. Replace. Clean or replace. Clean or replace. |
| Engine stalls easily. | 1. Fouled spark plug. 2. Defective signal coil or ignitor unit. 3. Defective fuel pump. 4. Clogged or defective fuel valve. 5. Clogged carburetor jet. 6. Valve clearance out of adjustment. |
Clean or replace. Replace. Replace. Clean or replace. Clean. Adjust. |
Troubleshooting and error codes
| Complaint | Symptom and possible causes | Remedy |
|---|---|---|
| Engine will not start or is hard to start. | Compression too low 1. Worn cylinder. 2. Worn piston ring. 3. Worn valve guide or improper valve seating. 4. Loose spark plug. 5. Broken, cracked, or damaged piston. 6. Slow cranking starter motor. 7. Mistimed valves. 8. Valve clearance out of adjustment. |
Replace. Replace. Repair or replace. Tighten. Replace See electrical section. Adjust. Adjus |
| Spark plug not sparking | 1. Damaged spark plug. 2. Damaged spark plug cap. 3. Fouled spark plug. 4. Wet spark plug. 5. Defective ignition coil. 6. Open or short in high-tension cord. 7. Defective pick-up coil or ignitor unit. |
Replace. Replace. Clean or replace. Clean and dry or replace. Replace. Replace. Replace. |
| No fuel reaching the carburetor | 1. Clogged hole in the fuel tank cap. 2. Defective fuel pump. 3. Clogged or defective fuel valve 4. Defective carburetor needle valve. 5. Clogged fuel hose. 6. Clogged fuel filter. |
Clean or replace. Replace. Clean or replace. Replace. Clean or replace. Clean or replace. |
| Engine stalls easily. | 1. Fouled spark plug. 2. Defective signal coil or ignitor unit. 3. Defective fuel pump. 4. Clogged or defective fuel valve. 5. Clogged carburetor jet. 6. Valve clearance out of adjustment. |
Clean or replace. Replace. Replace. Clean or replace. Clean. Adjust. |