Segment:
Cruiser motorcycle segment.
Target Audience:
Owners of Suzuki VS700, VS750, VS800 Intruder, and S50 models seeking to perform maintenance and repairs.
Competitors Contemporary:
Honda Shadow series, Yamaha Virago series, Kawasaki Vulcan series.
Engine Layout:
V-twin engine, known for its torque and classic cruiser styling.
Drivetrain:
Shaft drive, offering low maintenance compared to chain drives.
Styling:
Classic cruiser aesthetics with a comfortable riding position.
Benefits Of Manual:
Enables cost-effective repairs, proper maintenance for longevity, and a deeper understanding of the motorcycle's mechanics.
Primary Coverage:
Comprehensive repair and maintenance for Suzuki VS700, VS750, VS800 Intruder, and S50 models from 1997-2000.
Engine Coverage:
Engine overhaul, disassembly, assembly, tuning, diagnosis, and troubleshooting.
Drivetrain Coverage:
Shaft drive system maintenance, inspection, and repair.
Cooling System Coverage:
Radiator, coolant, fan, and associated component servicing.
Fuel Lubrication Coverage:
Carburetor systems, fuel pump, fuel lines, oil system, and lubrication procedures.
Emission Control Coverage:
Information on emission control systems and related adjustments.
Electrical System Coverage:
Wiring diagrams, ignition system, lighting, charging system, starter motor, and electronic components.
Chassis Coverage:
Frame, suspension (front and rear), steering, brakes, wheels, and tires.
Servicing Information Coverage:
General servicing procedures, torque specifications, and diagnostic aids.
Estimated Page Count:
Typically 300-600 pages for a factory service manual of this scope.
Type:
Factory Service Repair Manual
Compatibility:
Windows and Mac
Reader Requirement:
Adobe PDF Reader
Engine Systems:
V-twin engine architecture, cylinder heads, pistons, crankshaft, camshafts, valve train, lubrication, cooling, ignition, fuel delivery (carburetion).
Transmission Drivetrain:
Gearbox internal components, clutch operation, shaft drive system (driveshaft, final drive unit, universal joints).
Electrical Ignition:
Ignition coil, spark plugs, CDI unit, charging system (alternator/stator, regulator/rectifier), battery, starting system (starter motor, starter solenoid).
Braking Suspension Steering:
Front and rear brake systems (hydraulic, calipers, master cylinders, brake pads, brake fluid), front telescopic forks, rear monoshock or dual shock absorber suspension, steering head bearings, handlebars, throttle controls.
Fuel System:
Carburetor models (e.g., Mikuni BS36 or similar), fuel tank, fuel filter, fuel lines.
Exhaust Emission:
Exhaust system components, emissions control devices (if applicable for the target market).
Maintenance Procedures:
Oil changes, filter replacements, spark plug checks/replacement, air filter cleaning/replacement, coolant checks/replacement, chain/shaft drive lubrication and adjustment, brake fluid flush, tire pressure checks, bearing lubrication.
Tune Up Procedures:
Carburetor synchronization and adjustment, ignition timing checks, idle speed adjustment, valve clearance adjustments.
Engine Rebuild Procedures:
Complete engine disassembly, inspection of internal components (pistons, rings, valves, bearings), cylinder head reconditioning, gasket replacement, engine reassembly.
Electrical Diagnosis Repair:
Troubleshooting electrical faults using wiring diagrams, testing charging system components, diagnosing ignition system issues, repairing lighting circuits.
Suspension Steering Repair:
Fork seal replacement, shock absorber servicing, steering head bearing replacement, wheel bearing replacement.
Braking System Repair:
Brake pad replacement, caliper service, master cylinder overhaul, brake line replacement, brake bleeding.
Drivetrain Maintenance:
Shaft drive oil change, universal joint inspection, driveshaft boot inspection.
Depth:
Comprehensive, from basic owner maintenance to complete engine and chassis overhauls.
Diagnostics:
Includes diagnostic procedures for common issues, troubleshooting charts, and electrical system testing methods.
Special Tools:
Likely lists specific tools required for certain procedures, such as valve spring compressors or engine torque wrenches.
Torque Specs:
Detailed torque specifications for all critical fasteners throughout the motorcycle.
Configuration:
Air-cooled, four-stroke, 45-degree V-twin.
Displacement Approximate:
VS700: 699 cc, VS750: 742 cc, VS800: 805 cc.
Bore Stroke Approximate:
VS800GL: 83.0 mm x 74.4 mm (common across variants).
Compression Ratio Approximate:
9.3:1 (typical for VS800).
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder (two intake, two exhaust), pushrod actuated.
Horsepower Approximate Vs800:
Approx. 49-53 hp at 6,000-6,500 rpm.
Torque Approximate Vs800:
Approx. 63-65 Nm (46-48 ft-lbs) at 4,000-4,500 rpm.
Carburetor Type:
Mikuni BS36 (or similar) twin carburetors.
Fuel Delivery:
Diaphragm type fuel pump (likely).
Oil Capacity Approximate:
Approx. 2.5 - 3.0 liters with filter change.
Oil Type Recommendation:
Refer to manual for specific viscosity (e.g., 10W-40 or 20W-50 API SG or higher).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (check manual for exact specification).
Air Filter Service:
Inspect every 6,000 km (3,700 miles), clean or replace as needed.
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles) or as specified.
Valve Clearance Check:
Every 18,000 km (11,000 miles) or as specified.
Brake Fluid Change:
Every 2 years or as specified by manual.
Engine Oil Viscosity:
10W-40 or 20W-50 (refer to manual for specific ambient temperature ranges).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual).
Coolant Type:
Ethylene glycol-based antifreeze solution (50% mixture with distilled water).
Shaft Drive Oil Type:
Gear oil, GL-5 specification (e.g., SAE 80W-90).
Common Problems Note:
Typical issues might include carburetor performance degradation (clogging), aging electrical connectors, and wear on suspension components over time.
Carburetor Tuning:
Carburetors may require periodic cleaning and tuning due to fuel deposits.
Electrical Connections:
Corrosion or degradation of electrical connectors can lead to intermittent faults.
Drive Shaft Boot:
The driveshaft boot can degrade over time, allowing dirt to enter the final drive.
Suzuki Motorcycle Division:
Suzuki has a long history in motorcycle manufacturing, known for innovation and reliable engines, particularly in the V-twin cruiser segment with models like the Intruder line.
Intruder Line:
The Intruder line was Suzuki's entry into the popular cruiser market, characterized by its V-twin engines and classic styling. The VS700/750/800 represented a mid-size offering.
Production Period:
The VS800 Intruder was produced from the early 1990s through the early 2000s, with the S50 designation often used in later years or for specific market variants.
Manufacturing Location:
Typically manufactured in Japan by Suzuki Motor Corporation.
