Target Audience:
Do-it-yourself (DIY) owners and professional motorcycle mechanics.
Value Proposition:
Provides essential, factory-level technical information for maintaining and repairing the Suzuki VS series cruisers, saving time and money compared to dealership service.
Delivery Method:
Instant digital download, eliminating shipping costs and delays.
Content Highlight:
Extensive diagrams, illustrations, and step-by-step procedures for complex tasks.
Covered Models And Years:
1989, 1990, 1991, 1992 Suzuki VS700 Intruder, VS750 Intruder, VS800 Intruder, and S50 Boulevard (indicating a broad coverage including early models that evolved into the S50 designation).
Region Of Origin:
Likely North American market based on model designations, but applicable globally for mechanical aspects.
Estimated Page Count:
Typically between 300-500 pages for a comprehensive factory service manual of this era.
Type:
Factory Service Repair Manual
Format:
PDF (Digital Download)
Engine:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of major components like cylinders, pistons, crankshaft, camshafts, valve train, and timing components.
Fuel And Lubrication System:
Detailed procedures for carburetor servicing (likely Mikuni CV carbs), fuel pump operation, fuel tank maintenance, oil pump, oil passages, oil filter replacement, and lubrication system troubleshooting.
Cooling System:
Information on the liquid-cooled system, including radiator service, coolant replacement, water pump inspection and repair, thermostat operation, and hose routing.
Electrical System:
Comprehensive wiring diagrams, troubleshooting for ignition system (CDI, coils), starting system (starter motor, solenoid), charging system (alternator, regulator/rectifier), lighting, instrumentation, and auxiliary circuits.
Chassis:
Front suspension (forks, steering head bearings), rear suspension (shock absorbers, swingarm, bearings), braking system (front and rear caliper, master cylinders, brake lines, pads), wheel and tire service, and frame inspection.
Shaft Drive:
Detailed maintenance and repair procedures for the final drive shaft, universal joints, drive shaft housing, gears, and seals.
Emission Control:
Information related to emissions control systems specific to the model years, potentially including air injection systems or exhaust management.
Maintenance:
Periodic maintenance schedules, tune-up procedures (spark plug replacement, carburetor adjustment, ignition timing), fluid changes, filter replacements, and lubrication points.
Repair:
Step-by-step instructions for component removal, repair, and installation, including engine rebuilds, transmission servicing, brake caliper overhauls, and suspension component replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for various mechanical and electrical issues.
Rebuilds:
Complete instructions for rebuilding major assemblies such as engines, carburetors, brake systems, and suspension components.
Depth Of Coverage:
Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts, covering everything from basic maintenance to full engine and chassis overhauls.
Documentation Style:
Detailed step-by-step instructions, exploded diagrams, illustrations, and torque specifications.
Searchability:
Likely text-searchable PDF, allowing for quick location of specific information.
Printability:
Yes, printable, allowing users to create physical copies of sections or the entire manual.
Binding:
N/A (Digital PDF format, no physical binding)
Paper Type:
N/A (Digital PDF format, no physical paper)
Operating Systems:
WINDOWS and MAC
Required Software:
Adobe PDF Reader
Engine Type:
V-Twin, Liquid-Cooled, 4-Stroke
Displacement:
VS700: 699cc, VS750: 747cc, VS800: 796cc
Bore X Stroke:
VS700: 71.0 x 43.0 mm, VS750: 73.0 x 43.0 mm, VS800: 71.0 x 51.1 mm (typical values, exact may vary slightly)
Horsepower:
Approx. 50-60 HP (depending on specific model and tuning)
Torque:
Approx. 50-60 lb-ft (depending on specific model and tuning)
Carburetor Type:
Mikuni Constant Velocity (CV) Carburetors (likely dual carburetors)
Fuel Delivery:
Fuel pump driven, gravity feed from tank to carbs is unlikely for this era and configuration.
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves per cylinder (some variants may differ)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Instrumentation:
Classic analog gauges including speedometer, tachometer (on some models), and indicator lights for turn signals, neutral, oil pressure, and high beam. Manual covers diagnostic functions for these.
ABS:
Anti-lock Braking System (ABS) was not commonly available on these models in the early 90s. Manual will confirm for specific variants if present.
Charging System:
Standard alternator and regulator/rectifier system for battery charging. Manual provides testing procedures for these components.
Oil Change:
Typically every 3,000-5,000 miles (5,000-8,000 km) or annually, with specific recommendation in manual.
Valve Adjustment:
Usually every 10,000-15,000 miles (16,000-24,000 km), crucial for performance and longevity.
Spark Plug Replacement:
Every 6,000-10,000 miles (10,000-16,000 km), depending on plug type.
Engine Oil:
Suzuki recommends specific grades, typically SAE 10W-40 or 20W-50 motorcycle specific oil meeting API SG or higher. Manual will confirm exact viscosity and specification.
Coolant:
Ethylene glycol-based permanent antifreeze, mixed 50/50 with distilled water. Manual will specify type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact type and replacement intervals.
Final Drive Oil:
Likely hypoid gear oil, SAE 80W-90. Manual will confirm.
Carburetor Issues:
CV carburetor diaphragms can degrade over time, leading to poor throttle response or rough idle. Proper cleaning and adjustment are key.
Electrical Connections:
Corrosion on electrical connectors, especially ground points, can cause intermittent electrical problems. The manual's wiring diagrams are vital for troubleshooting.
Shaft Drive Maintenance:
Regular lubrication of the driveshaft splines and U-joints is essential to prevent wear and binding. Proper sealing is also critical.
Suzuki Legacy:
Suzuki is a major Japanese manufacturer with a long history in motorcycle production, known for innovation and performance across various segments including cruisers.
Intruder Lineage:
The VS Intruder series was Suzuki's entry into the V-twin cruiser market, aiming to compete with Japanese and American rivals. The VS800 evolved into the S50 Boulevard, showcasing Suzuki's strategy of modernizing and branding its cruiser line.
Manufacturing Location:
Primarily Japan, though some assembly or components may have originated from other Suzuki facilities.
