Suzuki VS800GLY 2000 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89259

Etiquetas: 2000 Misc Motorcycle Motorcycles Suzuki VS800GLY

Variantes de producto

Descripción

This manual covers the VS800GLY Intruder, a classic cruiser motorcycle produced in 2000. Renowned for its timeless design and the robust V-twin engine, the VS800GLY Intruder offers an accessible and enjoyable riding experience, fitting seamlessly into a heritage of reliable and performance-oriented motorcycles. Its engineering prioritizes comfortable cruising and a distinctive aesthetic, making it a popular choice among riders who appreciate traditional styling and dependable performance. This comprehensive service and repair manual provides detailed guidance for owners and technicians. It covers a wide array of essential areas, including engine mechanicals, fuel and ignition systems, transmission, chassis, brakes, and the electrical system. Within its approximately 300-400 pages, you will find procedures for scheduled maintenance, in-depth troubleshooting, and complete repair instructions for all major components. This resource is designed to empower users to maintain their VS800GLY Intruder effectively, ensuring its longevity and optimal performance.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VS800GLY Intruder

Year:

Codes

Model Code:

VS800GLY

👋 Introduction

Market Position

Category:

Cruiser Motorcycle

Target Audience:

Owners of Suzuki VS800GLY Intruder, DIY mechanics, Service technicians

Competitive Analysis

Competitors:

Honda Shadow VT600, Kawasaki Vulcan 750, Yamaha Virago XV750

Key Features Vehicle

Design Philosophy:

Classic cruiser styling with a V-twin engine, focus on accessible performance and comfortable riding.

Key Features Manual

Advantage Over Paper:

Easily searchable, bookmarkable, printable sections, accessible on multiple devices, no wear and tear.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Engine, Transmission, Chassis, Electrical System, Bodywork, Maintenance, Troubleshooting, Specifications

Page Count

Estimated Page Count:

300-400

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top end (cylinder head, valves), Piston and connecting rod, Crankshaft, Camshafts, Lubrication system, Cooling system (air-cooled specifics)

Fuel System:

Carburetor(s) (Mikuni BSW 36), Fuel pump, Fuel tank, Fuel lines

Ignition System:

CDI, Ignition timing, Spark plugs

Transmission Drivetrain:

Clutch operation, Gearbox internals, Shift mechanism, Final drive (shaft drive components)

Chassis Suspension:

Front fork (telescopic), Rear suspension (swingarm, monoshock), Frame inspection and repair

Brakes:

Front disc brake (caliper, rotor, master cylinder), Rear drum brake (if applicable), Brake fluid specifications, Bleeding procedures

Electrical System:

Battery, Charging system (alternator, regulator/rectifier), Starter motor, Lighting system (headlight, taillight, turn signals), Wiring diagrams, Fuses, Relays

Bodywork Styling:

Body panels, Seat, Fuel tank removal/installation, Fenders, Handlebars

Procedures Included

Scheduled Maintenance:

Oil changes, Filter replacement, Spark plug service, Air filter cleaning/replacement, Chain adjustment (if applicable, though shaft drive), Brake pad inspection/replacement, Coolant flush (if liquid-cooled), Valve clearance checks

Troubleshooting:

Diagnostic flowcharts, Common problem diagnosis (starting issues, misfires, electrical faults)

Engine Repair:

Engine disassembly and reassembly, Piston ring replacement, Valve seat grinding, Gasket replacement

Transmission Repair:

Gearbox overhaul, Clutch assembly replacement

Suspension Repair:

Fork seal replacement, Shock absorber replacement

Electrical Diagnostics:

Wiring harness repair, Component testing (stator, rectifier, starter)

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine rebuilds and electrical diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text (OCR applied)

Print Quality

Quality:

High resolution for clarity of diagrams and text

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, 2-valve-per-cylinder, SOHC V-twin

Displacement:

797 cc (48.6 cu. in.)

Bore X Stroke:

83.0 mm x 74.4 mm (3.27 in. x 2.93 in.)

Compression Ratio:

9.2:1

Performance

Horsepower Est:

50-55 HP (Approx.)

Torque Est:

60-65 Nm (Approx.)

Fuel System

Carburetor Type:

Single Mikuni BSW36

Fuel Capacity:

13.0 L (3.4 US gal)

Lubrication

Oil Type:

SAE 10W-40 API SG or SH

Oil Capacity W Filter:

2.5 L (2.6 US qt)

Ignition

Spark Plug Gap:

0.7-0.8 mm (0.028-0.031 in.)

Ignition Timing Static:

10° BTDC

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Shaft Drive

Fluid Spec

Transmission Oil:

API GL-5 SAE 80W-90 Gear Oil

Fluid Capacity

Final Drive Oil Capacity:

100 ml (0.11 US qt)

📐 Dimensions

Exterior

Length:

2350 mm (92.5 in.)

Width:

820 mm (32.3 in.)

Height:

1160 mm (45.7 in.)

Wheelbase:

1605 mm (63.2 in.)

Ground Clearance:

135 mm (5.3 in.)

Weights

Dry Weight:

203 kg (447.5 lbs)

Wet Weight Est:

220 kg (485 lbs)

Tire Sizes

Front Tire:

130/90-16M/C 67B

Rear Tire:

170/80-15M/C 77P

Wheel Specs

Front Wheel Type:

Cast aluminum

Rear Wheel Type:

Cast aluminum

🛡️ Safety Features

Ratings

Safety Certification:

DOT, ECE (as applicable for markets)

Active Features

Braking System:

Front disc, Rear drum (typically)

Passive Features

Lighting:

Halogen headlight, LED taillight (common for cruisers)

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, neutral indicator, high beam indicator). No advanced infotainment systems.

Driver Assistance

Features:

None (typical for this era of cruiser).

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles)

Spark Plug Replacement:

Every 15,000-20,000 km (9,000-12,000 miles)

Fluid Specifications

Brake Fluid:

DOT 4

Coolant:

N/A (Air-cooled)

Known Issues

Carburetor Issues:

Can be prone to gumming up if fuel is left standing, requiring cleaning and synchronization.

Electrical Connections:

Corrosion in connectors or grounding points can lead to intermittent electrical faults.

Shaft Drive Maintenance:

Requires periodic inspection and greasing of the shaft drive components to prevent wear.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long history of producing reliable and innovative motorcycles across various segments, known for their engineering and performance.

Model Evolution

Intruder Lineage:

The VS800 Intruder was part of Suzuki's successful cruiser line, evolving from earlier models and influencing later designs with its V-twin engine and distinctive styling.

Production

Production Years:

The VS800 Intruder was produced for many years, with the 2000 model being part of the refined second generation.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The VS800 Intruder is generally regarded as a reliable and well-built cruiser, popular for its comfortable ride and classic styling.