🏷️ Basic Information

Make:

Suzuki

Model:

Intruder VS800

Engine Type:

V-Twin

Body Style:

Cruiser

Vin Code Engine:

VS800

👋 Introduction

Positioning:

The Suzuki Intruder VS800 was positioned as a mid-size cruiser, offering a balance of performance, style, and comfortable riding for enthusiasts.

Competitors:

Competed with models such as the Honda Shadow 750, Yamaha Virago 750, and Kawasaki Vulcan 750 during its production run.

Features:

V-twin engine, shaft drive, comfortable cruiser ergonomics, timeless styling, reliable performance.

📋 Manual Details

Model Years Covered:

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997

Total Pages:

449

Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine:

Complete overhaul, inspection, adjustment, troubleshooting, lubrication, cooling system, fuel system (carburetor, fuel lines, pump), ignition system (spark plugs, ignition coils, timing), exhaust system, internal engine components (pistons, rings, crankshaft, camshafts).

Transmission Drivetrain:

Gearbox disassembly and assembly, clutch operation and adjustment, final drive (shaft drive system), lubrication, troubleshooting.

Chassis Frame:

Frame inspection, front fork assembly (disassembly, inspection, seal replacement), rear suspension (shock absorbers, linkage), swingarm, steering system (bearings, adjustment).

Electrical System:

Wiring diagrams, lighting (headlight, taillight, turn signals), battery, charging system (generator, regulator/rectifier), starter motor, ignition switch, fuses, relays, instrument panel, electrical component testing and troubleshooting.

Brakes:

Front and rear brake system inspection, caliper overhaul, master cylinder service, brake pad replacement, brake fluid flush and bleeding, disc inspection.

Fuel System:

Carburetor cleaning, adjustment, rebuilding, jetting, fuel tank inspection, fuel petcock operation, fuel lines.

Cooling System:

Radiator inspection, coolant type and capacity, fan operation (if applicable), thermostat.

Bodywork Fittings:

Body panel removal and installation, seat, fenders, exhaust pipes, handlebars, controls, cables.

General Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable, though VS800 is shaft drive), tire pressure checks, brake adjustments, lubrication points.

Troubleshooting:

Systematic diagnosis of common and uncommon problems, fault finding charts, symptom analysis.

Disassembly Assembly:

Step-by-step instructions for dismantling and reassembling all major components and sub-assemblies.

Repair Overhaul:

Detailed procedures for repairing worn or damaged components, including rebuilding carburetors, transmissions, and engines.

Adjustments:

Valve clearance adjustment, ignition timing, carburetor synchronization, clutch and brake lever free play.

Wiring Diagrams:

Comprehensive electrical schematics for easy identification and troubleshooting of electrical issues.

Depth Of Information:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed exploded diagrams, torque specifications, and wear limits.

📊 Manual Specifications

PDF Quality:

High-resolution, allowing for clear viewing and printing of diagrams and text.

Printability:

Yes, all pages are printable.

Binding:

Not applicable (Digital PDF)

Paper Type:

Not applicable (Digital PDF)

Software Needed:

Adobe Reader

Operating System Compatibility:

Windows, Mac, Linux OS

⚙️ Engine Specifications

Engine Type:

783cc (47.8 cu in) 45-degree V-twin, four-stroke, SOHC, 4 valves per cylinder

Bore X Stroke:

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

Compression Ratio:

9.3:1

Horsepower Estimated:

Approximately 50-55 HP (exact figures varied by year and market, typically around 50 HP at 6,500 RPM)

Torque Estimated:

Approximately 60-65 Nm (exact figures varied, typically around 62 Nm at 3,500 RPM)

Fuel Delivery:

Two Mikuni B27 carburetors (e.g., 34mm)

Fuel Tank Capacity:

Approximately 12.0 L (3.2 US gal)

Ignition System:

Digital CDI

Oil Type:

API SE or SF, SAE 10W-40 or 20W-50 motorcycle specific oil.

🔧 Transmission

Transmission Type:

5-speed constant mesh

Final Drive:

Shaft drive

Clutch Type:

Wet multi-plate

📐 Dimensions

Overall Length:

Approximately 2290 mm (90.2 in)

Overall Width:

Approximately 830 mm (32.7 in)

Overall Height:

Approximately 1150 mm (45.3 in)

Dry Weight:

Approximately 207 kg (456 lbs)

Wet Weight:

Approximately 222 kg (489 lbs)

🛡️ Safety Features

Safety Standards:

Follows relevant motorcycle safety regulations for its era. Manual emphasizes adherence to safety procedures during maintenance and repair.

Braking System:

Dual front disc brakes, single rear disc brake (specifications vary slightly by year).

Frame Construction:

Steel double cradle frame for stability.

💡 Technology Features

Infotainment Features:

Not applicable for this era of motorcycle; focus is on mechanical and electrical systems.

Assistance Systems:

Not applicable for this era of motorcycle.

Connectivity Features:

Not applicable for this era of motorcycle.

🔧 Maintenance

Engine Oil Change:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first.

Oil Filter Change:

At every oil change.

Spark Plug Replacement:

Approximately every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 8,000 km (5,000 miles) or annually.

Brake Fluid Type:

DOT 3 or DOT 4.

Coolant Type:

Suzuki Super Anti-freeze Long Life Coolant (or equivalent ethylene glycol-based coolant).

Final Drive Oil:

Suzuki Hypoid Gear Oil (or equivalent GL-5 80W-90).

Common Wear Items:

Carburetor performance (jetting, float levels), clutch wear, wheel bearings, fork seals, brake components.

Electrical Issues:

Corrosion on connectors, stator or regulator/rectifier failure can occur over time.

Engine Mount Bolts:

Refer to manual for specific torque values (e.g., cylinder head bolts, crankcase bolts).

Wheel Axle Nuts:

Refer to manual for specific torque values (e.g., front and rear axle nuts).

📚 Vehicle History

Manufacturer Heritage:

Suzuki has a long history of producing reliable and performance-oriented motorcycles, including a strong presence in the cruiser segment.

Evolution Period:

The VS800 Intruder was a significant model in Suzuki's cruiser lineup, consistently refined throughout its 1985-1997 production run. Later models saw minor updates and enhancements.

Production Years:

1985-1997

Manufacturing Origin:

Japan (primarily)

🏆 Awards & Recognition

Model Recognition:

While specific awards might not be widely documented, the Intruder VS800 was generally well-regarded for its blend of style, reliability, and rider comfort within the cruiser segment.