Suzuki VS750-800 GL Motorcycle Repair Manual 1985-1992

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Tipo: Motorcycle

Proveedor:

SKU: 113343

Etiquetas: 1985 1986 1987 1988 1989 1990 1991 1992 Intruder Motorcycle Motorcycles Suzuki VS750 GL VS800 GL

Variantes de producto

Descripción

This manual covers the VS750 and VS800 Intruder motorcycles, produced from 1985 to 1992. These V-twin, air-cooled cruisers established presence in the cruiser market, with the VS750 marking the introduction of the Intruder line. The VS800, introduced in 1992, offered an increase in displacement and refinements to the platform. This workshop service manual provides comprehensive information for owners and technicians working on various models including the GL, GLG, GLH, GLJ, GLK, GLFL, GLPL, GLFM, GLPM, and GLN variants. The purpose of this 408-page English-language workshop service and repair manual is to provide detailed guidance for the maintenance, repair, and troubleshooting of the VS750/VS800 Intruder. It covers all major systems, including the engine, fuel and lubrication systems, electrical components, chassis, suspension, brakes, and shaft drive. The manual includes step-by-step repair instructions, periodic maintenance procedures, diagnostic flowcharts, and essential technical specifications such as torque values and fluid capacities, offering factory-level detail for effective vehicle upkeep.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VS750/VS800 Intruder

Model Variant:

GL, GLG, GLH, GLJ, GLK, GLFL, GLPL, GLFM, GLPM, GLN

Year Range:

1985-1992

Codes

Chassis Code:

VS750, VS800

Generation

Generation Code:

First Generation Intruder

👋 Introduction

Market Position

Target Audience:

Owners, mechanics, and enthusiasts of Suzuki VS750/VS800 Intruder motorcycles from 1985-1992.

Competitive Analysis

Advantage Over Factory Cd:

Direct PDF download, no need for physical media or CD-ROM drives, similar content to factory shop manuals without the high cost.

Key Features

Accessibility:

Works on all PC-based Windows operating systems and Mac.

Instant Access:

Ready for immediate download upon purchase.

Cost Effectiveness:

Offers significant savings compared to purchasing official Suzuki factory shop manuals or CD-ROMs.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive workshop service and repair information for the Suzuki VS750/VS800 Intruder motorcycle from 1985 to 1992.

Page Count

Total Pages:

Manual Type

Manual Type:

Workshop Service/Repair Manual

Manual Quality:

Comprehensive Workshop Service Manual, similar to factory originals.

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, and troubleshooting.

Fuel Lubrication:

Fuel system (carburetors, fuel lines, fuel pump), lubrication system (oil pump, oil filter, oil flow).

Electrical:

Ignition system, lighting, charging system (stator, regulator/rectifier), starting system, wiring diagrams.

Chassis:

Frame, suspension (front forks, rear shock absorber), steering, wheels, brakes.

Shaft Drive:

Final drive unit, driveshaft, U-joints, and rear differential maintenance and repair.

Cooling System:

Radiator, coolant, thermostat, and related components (if applicable for specific variants).

Frame And Suspension:

Front fork service (oil, seals, springs), rear shock absorber maintenance and adjustment, steering bearing service.

Brakes And Wheels:

Brake system overhaul (master cylinders, calipers, wheel cylinders), brake fluid flushing, wheel bearing service, tire information.

Procedures Included

Periodic Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication points, and tune-up procedures.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Troubleshooting:

Diagnostic procedures and solutions for common problems and malfunctions.

Servicing Information:

General servicing advice, torque specifications, and special tool requirements.

Engine Rebuild:

Complete engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), reassembly, and performance tuning.

Carburetor Service:

Carburetor disassembly, cleaning, adjustment (idle speed, air/fuel mixture), synchronisation, and jetting information.

Technical Depth

Depth Of Coverage:

Factory-level technical detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete rebuilds and advanced diagnostics.

Diagnostic Capabilities:

Provides detailed diagnostic flowcharts and component testing procedures.

Specifications Data:

Includes critical technical data such as torque specifications for all fasteners, valve clearances, ignition timing, compression test readings, and fluid capacities.

Specific Models Covered

Model Codes And Years:

VS750GLG ('86), VS750GLH ('87), VS750GLJ ('88), VS750GLK ('89), VS750GLFL/GLPL ('90), VS750GLFM/GLPM ('91), VS800GLN ('92)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable PDF text

Compatibility:

Compatible with Windows and Mac operating systems.

Print Quality

Printable Pages:

Printable sections or entire manual

Binding Type

Binding:

Digital (PDF download)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-Twin, Four-stroke, SOHC, 4 valves per cylinder

Engine Displacement:

747cc (VS750), 795cc (VS800)

Engine Cooling:

Air-cooled (primarily for VS750 models, VS800 is also air-cooled).

Performance

Bore X Stroke Vs750:

85.0 mm x 66.0 mm

Bore X Stroke Vs800:

83.0 mm x 74.4 mm

Horsepower Vs750:

Approx. 60-65 hp (Varies by market and year, manual will specify exact figures)

Horsepower Vs800:

Approx. 63-68 hp (Varies by market and year, manual will specify exact figures)

Torque Vs750:

Approx. 45-50 lb-ft (Varies by market and year, manual will specify exact figures)

Torque Vs800:

Approx. 48-53 lb-ft (Varies by market and year, manual will specify exact figures)

Fuel System

Carburetion Type:

Twin Mikuni carburetors (e.g., VM34SS)

Fuel Delivery:

Fuel pump

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

Shaft drive

📐 Dimensions

Exterior

Wheelbase Approx:

1595 mm (62.8 in)

Weights

Dry Weight Approx Vs750:

215 kg (474 lbs)

Dry Weight Approx Vs800:

228 kg (503 lbs)

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle, not subjected to automotive crash testing standards)

Active Features

Brakes Front:

Single disc brake, hydraulic

Brakes Rear:

Drum brake, internal expanding shoe type

Passive Features

Lighting System:

Halogen headlight, taillight, brake light, turn signals (covered in electrical section).

💡 Technology Features

Infotainment

Infotainment System:

N/A (No integrated infotainment systems on this era of motorcycle)

Driver Assistance

Safety Features Tech:

Basic lighting and braking systems; no electronic rider aids like ABS or traction control.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/time intervals (typically 3,000-5,000 miles or 6-12 months, manual to confirm).

Spark Plug Replacement:

Refer to manual for specific mileage/time intervals (typically 6,000-10,000 miles, manual to confirm).

Air Filter Cleaning:

Refer to manual for specific mileage/time intervals (often every 3,000-5,000 miles or as needed based on conditions).

Fluid Specifications

Engine Oil Type:

Refer to manual for specific API service classification and viscosity grade (e.g., SAE 10W-40 or 20W-50, JASO MA recommended for wet clutches).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (manual to confirm specific type).

Coolant Type:

Permanent type antifreeze/coolant, 50/50 mix with distilled water (if liquid-cooled, manual to confirm specific coolant type and capacity).

Gearbox Oil Type:

Refer to manual for specific gear oil viscosity and API classification (typically GL-4 or GL-5).

Final Drive Oil Type:

Refer to manual for specific gear oil viscosity and API classification for the shaft drive unit.

Known Issues

Common Wear Items:

Clutch plates, fork seals, brake pads/shoes, drive shaft U-joints, carburetor diaphragm deterioration, and stator failure (all covered in troubleshooting/repair sections).

Electrical Problems:

Intermittent charging issues due to aging regulator/rectifier or stator, starter solenoid failure (detailed diagnostic steps in electrical section).

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Model Evolution

Intruder Lineage:

The VS750 Intruder, introduced in 1985, was Suzuki's first cruiser-style motorcycle. It established the 'Intruder' moniker and a design language that influenced subsequent models, including the larger VS800 which refined the platform. The VS800 was introduced in 1992, offering more displacement and refinements.

Production

Production Period:

1985-1992 for VS750, 1992 for VS800 (within this manual's scope).