Segment:
Cruiser motorcycle segment.
Target Demographic:
Riders seeking a comfortable, stylish cruiser with reliable Japanese engineering. Particularly popular for its V-twin engine and shaft drive, offering lower maintenance compared to chain-driven bikes.
Competitors:
Honda Shadow series, Yamaha Virago series, Kawasaki Vulcan series, Harley-Davidson Sportster (though a different price point and philosophy).
Engine Configuration:
Liquid-cooled, V-twin engine, emphasizing torque and relaxed riding.
Drive Type:
Shaft drive, offering a clean look and reduced maintenance compared to chain drive.
Styling:
Classic cruiser styling with a low seat height, pulled-back handlebars, and teardrop fuel tank.
Manual Value:
Provides comprehensive, manufacturer-sourced information essential for maintaining and repairing these models, saving owners significant costs compared to dealership service.
Powertrain:
Engine, transmission, clutch, final drive (shaft drive).
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires.
Braking System:
Front and rear brake caliper operation, master cylinders, hydraulic lines, brake pad replacement, bleeding procedures.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instruments, switches, wiring diagrams, diagnostic procedures.
Cooling System:
Liquid cooling system components, radiator, coolant flow, thermostat, fan (if applicable).
Bodywork:
Body panels, fenders, fuel tank, seat, exhaust system mounting, trim pieces.
Fuel System:
Carburetor(s) (likely dual Mikuni VM or BST models), fuel lines, fuel filter, fuel pump (if applicable).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though shaft drive), brake fluid changes, coolant flushes, general inspection points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults across all major vehicle systems, fault code interpretation (if applicable).
Repair:
Detailed step-by-step repair instructions for engine disassembly/reassembly, transmission overhauls, suspension component replacement, electrical component repair, body panel repair/replacement.
Diagnostics:
Component testing, circuit diagnosis, timing adjustments, carburetor synchronization and tuning.
Pre Delivery Inspection:
Procedures for initial setup and inspection before customer delivery.
Depth Level:
Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and wiring schematics.
Target Audience:
Professional technicians and experienced DIY mechanics.
Searchability:
Typically, PDF service manuals are text-searchable, allowing users to quickly find specific information.
Quality:
High-resolution scans or digital reproductions, suitable for printing.
Binding:
N/A (Digital PDF format)
Paper:
N/A (Digital PDF format)
Operating Systems:
All versions of Windows & Mac
Software:
Adobe PDF Reader
Type Vs750:
747cc (45.6 cu in) liquid-cooled, 45-degree V-twin, SOHC, 3 valves per cylinder (2 intake, 1 exhaust)
Type Vs800Gl:
805cc (49.1 cu in) liquid-cooled, 45-degree V-twin, SOHC, 3 valves per cylinder (2 intake, 1 exhaust)
Bore X Stroke Vs750:
83.0 mm x 68.5 mm (3.27 in x 2.70 in)
Bore X Stroke Vs800Gl:
83.0 mm x 74.4 mm (3.27 in x 2.93 in)
Compression Ratio:
Approx. 9.3:1 to 10.0:1 (varies slightly by year/region)
Horsepower Vs750:
Approx. 50-55 hp @ 6500-7000 rpm (estimated)
Horsepower Vs800Gl:
Approx. 55-60 hp @ 6500-7000 rpm (estimated)
Torque Vs750:
Approx. 45-50 lb-ft @ 4000-5000 rpm (estimated)
Torque Vs800Gl:
Approx. 50-55 lb-ft @ 4000-5000 rpm (estimated)
Carburetion:
Dual Mikuni carburetors (likely BST36 for VS800GL, potentially VM34SS or similar for VS750).
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher (as per manual recommendations).
Fuel Tank Capacity:
Approx. 13 Liters (3.4 US Gallons) for VS750, 12 Liters (3.2 US Gallons) for VS800GL.
Oil Type:
API SE/SF or SG classification, SAE 10W-40 viscosity grade motorcycle oil.
Oil Capacity With Filter:
Approx. 3.0 - 3.2 Liters (3.1 - 3.4 US Quarts)
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with electronic ignition advance.
Spark Plugs:
Commonly NGK DPR7EA-9 or similar, refer to manual for exact specifications and gap.
Type:
5-speed constant mesh, claw-shift transmission.
Clutch Type:
Wet, multi-plate clutch, cable-actuated.
Final Drive:
Shaft drive with universal joint, enclosed in a swingarm.
Transmission Oil Type:
API GL-4 SAE 80W gear oil.
Transmission Oil Capacity:
Approx. 0.7 Liters (0.74 US Quarts)
Wheelbase Vs750:
Approx. 1560 mm (61.4 in)
Wheelbase Vs800Gl:
Approx. 1565 mm (61.6 in)
Seat Height:
Approx. 700-720 mm (27.6-28.3 in), very low for a cruiser.
Dry Weight Vs750:
Approx. 197 kg (434 lbs)
Dry Weight Vs800Gl:
Approx. 206 kg (454 lbs)
Gross Vehicle Weight Rating:
Refer to owner's manual or chassis plate for specific GVWR.
Crash Test Ratings:
N/A (Motorcycles are not typically subjected to standardized crash testing like cars; safety focus is on rider protection and vehicle stability).
Braking System Features:
Dual front disc brakes (on most models, single on early VS750), single rear disc brake. ABS was not a common feature on these models during this period.
Lighting:
Halogen headlamp, bright tail and brake lights, turn signals.
Frame Construction:
Steel cradle frame, designed for stability and handling.
Tire Size Front:
Commonly 100/90-19 or 110/90-18.
Tire Size Rear:
Commonly 170/80-15 or 140/80-15.
Infotainment System:
N/A (Basic motorcycle instrumentation typical for the era: speedometer, tachometer (on some models), odometer, trip meter, warning lights).
ABS:
Not generally available on these models, especially earlier ones. Later models might have seen it as a rare option.
Connectivity Features:
N/A (No electronic connectivity features like Bluetooth or smartphone integration).
Efi Vs Carburetion:
Carburetor-based fuel delivery system. The manual will cover tuning, synchronization, and rebuilding of these carburetors.
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first, depending on riding conditions. Refer to manual for specific mileage/time.
Spark Plug Replacement:
Typically around 10,000-15,000 km (6,000-9,000 miles). Manual will specify exact interval and check.
Valve Clearance Check:
Initial check often at 1,000 km (600 miles), then every 10,000-15,000 km (6,000-9,000 miles).
Brake Fluid Change:
Every 12-24 months or as per manual, due to hygroscopic nature of brake fluid.
Engine Oil:
SAE 10W-40, API SE/SF/SG.
Cooling System Coolant:
Permanent type antifreeze coolant (ethylene glycol based), 50/50 mix with distilled water. Specific Suzuki coolant recommendations may apply.
Fork Oil:
Refer to manual for viscosity grade and quantity (typically around Showa SS-8 or equivalent, 10W).
Brake Fluid:
DOT 3 or DOT 4.
Final Drive Oil:
API GL-4 SAE 80W gear oil.
Carburetor Issues:
Diaphragm failures in constant-velocity (CV) carbs, leading to poor fuel mixture, stalling, or off-idle hesitation. Gumming from infrequent use.
Charging System Reliability:
Regulator/rectifier units can be a failure point on some older Japanese motorcycles, leading to charging issues. Stator windings can also fail.
Cooling System Leaks:
Hose degradation or radiator corrosion can lead to coolant leaks over time. Water pump seals can also fail.
Electrical Connection Corrosion:
Corrosion in connectors, especially for the charging system and ignition, can cause intermittent faults.
Recommended Parts Suppliers
Example Suppliers:
Suzuki OEM, Motion Pro, EBC Brakes, K&L Supply, Sudco (for carb parts).
Suzuki Motorcycle Legacy:
Suzuki has a long history of producing reliable and innovative motorcycles, known for their engines and overall build quality across various segments including sportbikes, standards, and cruisers.
Vs750 Introduction:
The VS750 Intruder was introduced in 1985 as Suzuki's entry into the burgeoning Japanese cruiser market, directly competing with models from Honda, Yamaha, and Kawasaki. It established the V-twin cruiser platform for Suzuki.
Vs800Gl Transition:
In 1992, the VS750 was largely replaced by the VS800GL Intruder, which featured an increase in displacement to 805cc, improved styling, and often minor chassis updates. The VS800GL continued production with minimal changes for many years, proving its enduring design.
Manufacturing Locations:
Primarily manufactured in Japan by Suzuki Motor Corporation.
Sales Performance:
The Intruder line was generally well-received for its value, reliability, and styling, making it a popular choice for riders entering the cruiser segment or seeking an alternative to American brands.
Industry Awards:
While specific awards for these particular models are not widely publicized, the Intruder line was recognized for its blend of styling, performance, and affordability in the cruiser segment.
Reliability Reputation:
Generally considered reliable with proper maintenance, typical of Suzuki engineering. Known for solid V-twin engines and robust drivetrains.
