🏷️ Basic Information

Make:

Suzuki

Model:

VS800GL Intruder

Vin Decoder Common First Digit:

4 (USA built)

Vin Decoder Common Tenth Digit:

Model year identifier

👋 Introduction

Motorcycle Segment:

Cruiser motorcycle

Target Audience:

Suzuki Intruder owners, mechanics, enthusiasts seeking to maintain or repair their motorcycles

Key Competitors:

Honda Shadow, Yamaha Virago, Kawasaki Vulcan, Harley-Davidson Sportster (in spirit and market segment)

Manual Advantage:

Provides detailed, accurate information essential for DIY maintenance and professional repair, saving money and ensuring longevity

Diagnostic Support:

Facilitates efficient fault finding through structured troubleshooting guides

📋 Manual Details

Covered Years:

1985-1997

Covered Models:

Suzuki VS700 Intruder, VS800 Intruder, VS800GL Intruder

Estimated Page Count:

300-400 pages (estimated based on typical Suzuki service manuals of this era)

Type:

Service Repair Manual

Language:

English

Format:

Digital (likely PDF, based on modern sales, but could be printed)

📖 Manual Coverage

Engine:

Disassembly, assembly, inspection, diagnosis, tuning, lubrication, cooling, fuel delivery (carburetor), ignition system, starting system

Transmission:

Clutch operation, gearbox inspection and repair, shift mechanism, maintenance

Drivetrain:

Shaft drive maintenance, rear differential inspection, propeller shaft, U-joints

Suspension:

Front fork service (oil changes, seal replacement), rear shock absorber replacement, linkage inspection

Brakes:

Front and rear brake system service, caliper overhaul, master cylinder inspection, hydraulic system bleeding, pad and shoe replacement

Electrical:

Wiring diagrams, charging system (stator, regulator/rectifier), ignition system components, lighting, starter motor, battery maintenance, troubleshooting electrical faults

Fuel System:

Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable)

Cooling System:

Air-cooled engine specifics, airflow management

Frame And Bodywork:

Chassis inspection, removal and installation of body panels, seat, fenders, fuel tank, handlebars

Maintenance:

Regular service checks, oil changes, filter replacements, chain adjustment (if applicable to earlier models/variations), spark plug replacement, brake fluid flush, coolant checks (if applicable)

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault finding charts

Repair Overhaul:

Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment

Technical Adjustments:

Carburetor synchronization, idle speed adjustment, ignition timing (if applicable), valve clearance adjustment

Wiring Diagrams:

Comprehensive electrical system diagrams for component identification and troubleshooting

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds)

Diagram Quality:

High-quality diagrams, pictures, and illustrations for clarity

Instruction Style:

Easy-to-read text sections with step-by-step instructions

Efficiency Focus:

Instructions designed for correct and efficient repairs, saving time and avoiding costly mistakes

📊 Manual Specifications

Digital Format:

PDF (assumed, ideal for searchability and printing)

Diagram Resolution:

High resolution, suitable for detailed viewing and printing

Physical Format Binding:

Comb-bound or perfect-bound (if printed)

Physical Format Paper:

Durable paper stock, resistant to shop fluids (if printed)

⚙️ Engine Specifications

Configuration:

V-twin, 4-stroke

Vs700 Displacement:

699 cc (42.7 cu. in.)

Vs800 Displacement:

798 cc (48.7 cu. in.)

Vs700 Bore X Stroke:

74.0 x 81.0 mm (2.91 x 3.19 in.)

Vs800 Bore X Stroke:

83.0 x 74.4 mm (3.27 x 2.93 in.)

Vs700 Compression Ratio:

9.3:1

Vs800 Compression Ratio:

9.3:1

Vs700 Horsepower Approx:

40-50 HP (estimate, varies by market and tuning)

Vs800 Horsepower Approx:

50-60 HP (estimate, varies by market and tuning)

Carburetion Type:

Dual Mikuni carburetors (e.g., VM26SS for VS700, possibly larger for VS800)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Approximately 3.2 US gallons (12 Liters)

🔧 Transmission

Type:

5-speed manual

Drive Type:

Shaft drive

Clutch Type:

Wet, multi-plate

📐 Dimensions

Vs700 Length Approx:

2245 mm (88.4 in.)

Vs800 Length Approx:

2355 mm (92.7 in.)

Vs700 Width Approx:

800 mm (31.5 in.)

Vs800 Width Approx:

820 mm (32.3 in.)

Vs700 Height Approx:

1155 mm (45.5 in.)

Vs800 Height Approx:

1160 mm (45.7 in.)

Vs700 Dry Weight Approx:

187 kg (412 lbs)

Vs800 Dry Weight Approx:

202 kg (445 lbs)

Vs700 Wet Weight Approx:

206 kg (454 lbs)

Vs800 Wet Weight Approx:

221 kg (487 lbs)

🛡️ Safety Features

Safety Certification:

Standard motorcycle safety certifications for the respective production years.

Braking System:

Front hydraulic disc brake, Rear drum brake (or disc on some later models/variants)

Lighting:

Headlight, taillight, brake light, turn signals

💡 Technology Features

Features:

Basic motorcycle instrumentation: speedometer, odometer, tachometer (on some models), fuel gauge, indicator lights.

Features:

N/A (vehicles of this era did not feature advanced electronic driver assistance systems).

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles or 6-12 months, refer to manual for specifics.

Spark Plug Replacement:

As per manual recommendations, typically between 6,000-12,000 miles.

Air Filter Cleaning Replacement:

Check at regular intervals, replace as needed based on operating conditions.

Brake Fluid Flush:

Recommend every 2 years or as per manual's mileage interval.

Engine Oil Type:

API SE, SF, or SG grade motorcycle oil, viscosity typically 10W-40 or 20W-50 (refer to manual for exact specification).

Engine Oil Capacity:

Approximately 2.4-2.8 Liters (2.5-3.0 US Quarts) with filter change (refer to manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual).

Gearbox Oil Type:

Hypoid gear oil (API GL-4 or GL-5) or specified Suzuki gear oil.

Carburetor Performance:

Can suffer from fuel gumming if left sitting, requiring cleaning and synchronization. Idle instability can occur.

Ignition System:

CDI unit failures or weak spark can occur with age. Stator output can degrade.

Electrical Connections:

Corrosion or loose connections in wiring harnesses, especially at grounds and connectors, can lead to intermittent electrical faults.

Rear Shock ABSorbers:

Original shocks may lose damping ability over time, requiring replacement for optimal ride and handling.

Fuel Petcock:

Diaphragm can degrade, leading to fuel leaks or poor fuel flow. Often requires rebuild or replacement.

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation

Motorcycle Legacy:

Suzuki has a long history of producing reliable and performance-oriented motorcycles across various segments.

Vs700 Introduction:

Introduced in 1985 as Suzuki's entry into the burgeoning American cruiser market, directly competing with models from Harley-Davidson and Japanese rivals.

Vs800 Development:

The VS800 Intruder evolved from the VS700, primarily with an increase in engine displacement to better compete in its class and meet market demands. It continued the styling and engineering principles of the original.

Styling Influence:

Characterized by its 'Long-and-low' profile, teardrop fuel tank, extensive chrome detailing, and a pronounced V-twin engine, defining the modern Japanese cruiser aesthetic.

Production Period:

1985 - 1997 (for the models covered by this manual)

🏆 Awards & Recognition

Market Reception:

Well-received for its styling, reliability, and value proposition in the cruiser market during its production run.