Suzuki VS800 1992-2009 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Suzuki Model: VS800 Intruder Generation Generation: First Generation (VS Series) Codes Chassis Code: VS800GL 👋 Introduction Market Position Market Segment: Cruiser motorcycle, known for its...

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Taper: Motorcycle

Distributeur:

UGS: 420419

Mots clés: 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Intruder Motorcycle Motorcycles Suzuki VS800

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VS800 Intruder

Generation

Generation:

First Generation (VS Series)

Codes

Chassis Code:

VS800GL

👋 Introduction

Market Position

Market Segment:

Cruiser motorcycle, known for its V-twin engine and classic styling.

Competitive Analysis

Key Competitors:

Yamaha Virago, Honda Shadow, Kawasaki Vulcan (in their respective displacement classes).

Key Features

Engine Configuration:

Air-cooled, 45-degree V-twin, SOHC, 3 valves per cylinder.

Styling:

Classic cruiser aesthetic with a low seat height, teardrop fuel tank, and prominent V-twin engine.

Drivetrain:

Shaft drive, offering low maintenance compared to chain drives.

📋 Manual Details

Coverage Areas

Model Years Covered:

1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine System:

Comprehensive coverage including disassembly, assembly, diagnosis, troubleshooting, and repair of the V-twin engine.

Fuel System:

Detailed procedures for carburetor inspection, cleaning, adjustment, fuel delivery system, and fuel tank maintenance.

Ignition System:

Information on ignition timing, spark plugs, CDI unit, coils, and troubleshooting ignition-related issues.

Transmission System:

Exploded diagrams and procedures for clutch operation, gear shifting mechanism, transmission case, and related components.

Frame And Suspension:

Detailed instructions for front fork maintenance, rear shock absorber inspection and replacement, frame inspection, and steering system servicing.

Brakes:

Coverage of front and rear brake systems, including hydraulic fluid replacement, caliper maintenance, brake pad replacement, and bleeding procedures.

Electrical System:

Wiring diagrams, troubleshooting guides for lighting, starting system, charging system (alternator/stator, regulator/rectifier), and instrument panel.

Cooling System:

Information on liquid cooling system maintenance, coolant specifications, and radiator service (though the VS800 is air-cooled, this may be general reference).

Bodywork And Trim:

Procedures for removal and installation of body panels, fenders, seat, and other external components.

Procedures Included

Routine Maintenance:

Includes oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, and general inspections.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, often presented in a flow-chart format.

Disassembly And Assembly:

Step-by-step instructions for removing, disassembling, cleaning, inspecting, reassembling, and installing all major components.

Repair And Rebuild:

Detailed guidance on rebuilding major assemblies like the engine, transmission, and suspension components.

Adjustments:

Instructions for setting idle speed, valve clearance, carburetor synchronization, clutch and brake lever free play, and suspension settings.

Technical Specifications:

Includes torque specifications for critical fasteners, fluid capacities, wear limits, and diagnostic data.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to complex engine and transmission rebuilds. Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution PDF, ensuring clear text and legible diagrams.

Print Quality

Printability:

Fully printable, allowing users to print specific sections or the entire manual for physical use.

Binding Type

Binding Type Digital:

Digital Download (PDF)

Paper Type

Paper Type Digital:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, air-cooled, V-twin

Displacement:

805 cc (49.1 cu in)

Bore X Stroke:

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

Valve Train:

SOHC, 3 valves per cylinder (2 intake, 1 exhaust)

Performance

Horsepower:

Approx. 50-55 HP (figures vary by region and specific tuning)

Torque:

Approx. 65-70 Nm (48-52 lb-ft)

Fuel System

Carburetion:

Dual Mikuni BSR34 carburetors

Fuel Capacity:

Approx. 3.2 US gallons (12 liters)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet multi-plate

Final Drive:

Shaft drive

📐 Dimensions

Exterior

Length:

Approx. 2245 mm (88.4 in)

Width:

Approx. 780 mm (30.7 in)

Height:

Approx. 1140 mm (44.9 in)

Weights

Dry Weight:

Approx. 193 kg (425 lbs)

Wet Weight:

Approx. 206 kg (454 lbs)

🛡️ Safety Features

Ratings

Safety Features Overview:

As a motorcycle from this era, safety features are primarily mechanical and rider-focused, with emphasis on braking and handling.

Active Features

Braking System:

Dual hydraulic disc front brake, single hydraulic disc rear brake.

Passive Features

Lighting System:

Halogen headlamp, taillight, brake light, and turn signals.

💡 Technology Features

Infotainment

Infotainment System:

N/A - This is a classic cruiser motorcycle with no integrated infotainment system. Audio systems (if any) would be aftermarket additions.

Driver Assistance

Driver Assistance Features:

N/A - No electronic rider aids like ABS or traction control were standard or commonly available during this model's production run.

Connectivity

Connectivity Features:

N/A - No onboard connectivity features.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 3,000-5,000 miles or annually, as per manual recommendations.

Spark Plug Replacement:

Recommended at approximately 7,500-10,000 mile intervals.

Valve Clearance Check:

Often recommended at first major service (e.g., 7,500 miles) and then at longer intervals thereafter.

Fluid Specifications

Engine Oil Type:

API SG or higher, JASO MA certified 10W-40 or 20W-50 (refer to manual for exact viscosity based on temperature).

Engine Oil Capacity:

Approx. 2.4 liters (2.5 US qt) without filter change, 2.6 liters (2.7 US qt) with filter change.

Brake Fluid:

DOT 4 or DOT 5.1 (check manual for compatibility as DOT 5.1 can be silicone-based).

Final Drive Oil Type:

Hypoid gear oil (e.g., SAE 80W-90).

Known Issues

Carburetor Issues:

Carburetors can be prone to gumming up if the bike sits for extended periods without fuel stabilizer; requires periodic cleaning and synchronization.

Stator Failure:

Some models can experience stator failure, leading to charging system issues.

Clutch Slippage:

With high mileage, clutch plates may wear, leading to slippage.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Division:

Suzuki has a long history in motorcycle manufacturing, known for innovation and reliable engines across various segments.

Model Evolution

Vs800 Intruder Placement:

The VS800 Intruder was a key model in Suzuki's cruiser lineup, establishing the 'Intruder' family.

Production

Production Start Year:

Production End Year:

2009 (for this specific generation/manual coverage)

🏆 Awards & Recognition

Recognitions

Model Recognition:

The VS800 Intruder was generally well-received for its V-twin character, comfortable riding position, and reliable shaft drive, making it a popular choice in the cruiser segment.