Suzuki VS800GLW 1998 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89257

Etiquetas: 1998 Misc Motorcycle Motorcycles Suzuki VS800GLW

Variantes de producto

Descripción

The 1998 Suzuki VS800GLW Intruder is a cruiser motorcycle renowned for its distinctive low-slung styling and reliable V-twin engine. Designed to offer riders a classic cruiser experience with manageable power delivery, this model features a 805 cc air-cooled V-twin engine, a 5-speed manual transmission, and a low-maintenance shaft drive. Its engineering emphasizes a comfortable riding position and accessible performance, making it a popular choice for those seeking a stylish and dependable cruiser. The VS800GLW Intruder embodies Suzuki's commitment to producing quality motorcycles that balance aesthetic appeal with practical functionality. This comprehensive service and repair manual provides detailed information essential for the maintenance, troubleshooting, and repair of the 1998 Suzuki VS800GLW Intruder. Covering all major systems, including the engine, transmission, brakes, and electrical components, the manual offers step-by-step procedures, diagnostic charts, and technical specifications. Its scope includes routine maintenance schedules, component overhauls, and in-depth troubleshooting guides, making it an invaluable resource for both DIY enthusiasts and professional technicians aiming to keep this classic cruiser in optimal condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VS800GLW Intruder

Year:

Codes

Chassis Code:

VS800GLW

👋 Introduction

Market Position

Category:

Cruiser Motorcycle

Target Audience:

Riders seeking reliable cruiser performance with classic styling

Competitive Analysis

Competitors:

Honda Shadow series, Yamaha Virago/V-Star series, Kawasaki Vulcan series

Key Features

Design Philosophy:

Emphasis on low-slung styling, V-twin power, and shaft drive for reduced maintenance

Value Proposition:

Reliable and accessible cruiser for its era, known for its distinctive styling and manageable power delivery

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams

Page Count

Estimated Pages:

Approximately 300-400

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed overhaul procedures, component testing, ignition system, fuel system (carburetor specifics)

Transmission:

Clutch operation, gear shifting mechanisms, final drive (shaft drive) maintenance

Brakes:

Hydraulic system, caliper service, pad replacement, master cylinder overhaul

Electrical:

Full wiring diagrams, starter system, charging system, lighting, ignition troubleshooting

Suspension:

Front fork service (oil, seals), rear shock absorber replacement, linkage maintenance

Frame And Body:

Component removal/installation, chassis alignment basics, fluid checks

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes (oil, brake, final drive), filter replacements, spark plug service

Repair:

Engine rebuild, transmission disassembly, carburetor tuning, electrical component repair, brake bleeding

Troubleshooting:

Diagnostic charts for common running issues, electrical faults, starting problems

Diagnostics:

Component testing procedures, specification checks (e.g., compression, ignition timing)

Technical Depth

Depth:

Comprehensive, suitable for DIY enthusiasts and professional technicians

Diagnostics Level:

Advanced diagnostic procedures and troubleshooting guides

Rebuild Procedures:

Detailed step-by-step instructions for complete engine and transmission overhauls

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable text and clear diagrams

Print Quality:

Printable, allowing for physical copy creation

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

V-Twin, Four-Stroke

Displacement:

805 cc

Bore X Stroke:

83.0 mm x 74.4 mm

Cooling System:

Air-Cooled

Valve Train:

SOHC, 2 valves per cylinder

Compression Ratio:

9.3:1

Performance

Horsepower Est:

Approximately 50 HP

Torque Est:

Approximately 47 lb-ft (64 Nm)

Fuel System

Carburetor:

Mikuni BSR36 (2 x 36mm) with Accelerator Pump

Fuel Capacity:

13.0 Liters (3.4 US gal)

Oil System

Oil Capacity W Filter:

2.7 Liters (2.9 US qt)

Oil Type Spec:

API SE, SF, or SG; SAE 20W-40 recommended (refer to manual for precise specification)

🔧 Transmission

Standard

Type:

5-Speed Manual

Clutch:

Wet, Multi-plate

Final Drive:

Shaft Drive

Features

Gear Ratios:

Refer to manual for specific gear ratios

Fluid Spec

Final Drive Oil Type:

API GL-5 SAE 80W-90 hypoid gear oil (refer to manual for precise specification)

📐 Dimensions

Exterior

Length:

2345 mm (92.3 in)

Width:

845 mm (33.3 in)

Height:

1160 mm (45.7 in)

Wheelbase:

1605 mm (63.2 in)

Ground Clearance:

135 mm (5.3 in)

Seat Height:

720 mm (28.3 in)

Weights

Dry Weight:

192 kg (423 lbs)

Wet Weight Est:

211 kg (465 lbs)

Tires

Front Tire:

130/90-16 M/C 67B

Rear Tire:

170/80-15 M/C 77B

Wheels

Front Wheel:

MT3.00 x 16

Rear Wheel:

MT4.50 x 15

🛡️ Safety Features

Ratings

Safety Certifications:

Meets all applicable US EPA, DOT, and California Air Resources Board standards for its model year.

Active Features

Braking System:

Front: Hydraulic Disc; Rear: Drum Brake (standard for this model year)

Passive Features

Lighting:

Halogen Headlight, LED Taillight, Incandescent Turn Signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high beam indicator)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months (refer to manual for exact interval and conditions)

Spark Plug Replacement:

Every 8,000 km (5,000 miles) or 12 months

Air Filter Cleaning Replacement:

Clean every 4,000 km (2,500 miles), replace as needed or every 12,000 km (7,500 miles)

Final Drive Oil Change:

Every 8,000 km (5,000 miles) or 12 months

Fluid Specifications

Engine Oil Viscosity:

SAE 20W-40 recommended (confirm with manual for precise range and conditions)

Brake Fluid Type:

DOT 4 (refer to manual for confirmation)

Fork Oil Type Viscosity:

SUS 32 or ISO VG 10 (refer to manual for exact type and quantity)

Known Issues

Carburetor Issues:

Potential for gumming if fuel sits, requires periodic cleaning and adjustment. Accelerator pump can wear.

Electrical Connectors:

Corrosion on electrical connectors, especially in high-humidity environments, can lead to intermittent issues.

Shaft Drive Maintenance:

Regularly check final drive gear oil level and condition. Universal joint boots can degrade over time.

Fork Seals:

Front fork seals can degrade and leak over time, requiring replacement.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki has a long history in motorcycles, known for innovation in engine technology and performance across various segments, including sportbikes, cruisers, and off-road.

Model Evolution

Intruder Lineage:

The VS800 Intruder (and its variants like the GLW) was part of Suzuki's cruiser lineup, competing with established Japanese and American models by offering a V-twin experience with distinctive styling.

Production

Production Years:

The VS800GL Intruder platform was produced for many years, with the VS800GLW specifically denoting a 1998 model year configuration.

Manufacturing Location:

Likely assembled in Japan, as per Suzuki's manufacturing practices for this era.

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Generally well-received for its styling and comfortable riding position, often praised for its value as an entry-level or mid-size cruiser.

Ratings

Reliability Perception:

Suzuki's reputation for building reliable motorcycles is generally extended to the Intruder line, with proper maintenance.