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Suzuki VS750 1988 1989 1990 1991 Workshop Service Repair Manual

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The VS750 Intruder, also known simply as the Intruder, is a V-Twin motorcycle that established Suzuki's presence in the cruiser market during its first generation. Produced from 1985 to 1991,...
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Type: Motorcycle
Vendor:
Sku: 155876
Suzuki VS750 1988 1989 1990 1991 Workshop Service Repair Manual
The VS750 Intruder, also known simply as the Intruder, is a V-Twin motorcycle that established Suzuki's presence in the cruiser market during its first generation. Produced from 1985 to 1991, with the specific VS750 models covered by this manual manufactured between 1988 and 1991, this air-cooled cruiser emphasized relaxed styling and rideability. Its design philosophy centered on a shaft-driven V-twin engine, offering an approachable performance with approximately 50-55 horsepower and around 60 Nm of torque, making it a competitive option against contemporaries like the Honda Shadow and Yamaha Virago. The VS750 was generally well-received for its characteristic V-twin sound and dependable performance, contributing to Suzuki's heritage in motorcycle manufacturing. This workshop service repair manual provides comprehensive, step-by-step instructions for the maintenance, troubleshooting, and repair of the VS750 Intruder. Covering a total of 539 pages in English, it details all major systems including engine mechanicals, fuel and ignition systems, transmission, drivetrain, suspension, brakes, and electrical components. The manual includes procedures for regular servicing, adjustments, disassembly, assembly, and installation, supported by pictorial diagrams, exploded diagrams, and technical specifications. It is an essential resource for mechanics, DIY enthusiasts, and owners seeking to maintain the reliability and longevity of their VS750 Intruder, offering detailed guidance on common wear items and crucial maintenance intervals.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
VS750 Intruder
Model Nickname:
Intruder
Engine Type:
V-Twin Motorcycle
Generation
Generation:
First Generation (VS750)
Codes
Vin Code:
See manual for VIN details
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle
Target Audience:
Mechanics, DIY enthusiasts, owners of Suzuki VS750 Intruder
Competitive Analysis
Competitors Era:
Honda Shadow, Yamaha Virago, Kawasaki Vulcan (similar displacement cruisers of the late 80s/early 90s)
Key Features
Design Philosophy:
Shaft-driven V-twin cruiser emphasizing relaxed styling and rideability
Manual Purpose:
Provide comprehensive, step-by-step instructions for repair, maintenance, and adjustments.
📋 Manual Details
Coverage Areas
Years Covered:
1988, 1989, 1990, 1991
Regions Covered:
Global (specifications may vary by region, refer to manual for specifics)
Page Count
Total Pages:
539
Manual Type
Type:
Workshop Service Repair Manual
Format:
PDF
Language
Language:
English
File Specifications
Printability:
Yes
Compatibility:
Windows, Mac, Linux OS
Required Software:
Adobe Reader
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, overhaul, internal components, cylinder head, pistons, crankshaft, valve train
Engine Fuel System:
Carburetor(s) servicing, fuel pump, fuel lines, fuel tank
Engine Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit
Engine Cooling System:
Radiator, coolant, thermostat, hoses (where applicable, VS750 is air-cooled)
Transmission:
Clutch operation, gearbox disassembly/assembly, gear ratios, shift mechanism
Drivetrain:
Shaft drive system maintenance, universal joints, final gear case
Suspension:
Front forks (telescopic) overhaul, rear shock absorber(s) inspection/replacement, suspension linkages
Brakes:
Front and rear brake system service, caliper overhaul, brake pad replacement, brake fluid, master cylinder
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting, switches, fuses, relays
Frame And Bodywork:
Frame inspection, body panel removal/installation, seat, fuel tank, handlebars
Wheels And Tires:
Wheel bearing service, tire pressure, tire replacement
Lubrication System:
Oil specifications, oil change procedures, oil filter replacement
Procedures Included
Maintenance:
Regular servicing, lubrication, adjustments, periodic checks
Troubleshooting:
Diagnosis of common problems, fault finding, error codes (if applicable)
Repair:
Step-by-step instructions for component repair and replacement
Disassembly:
Detailed procedures for taking components apart
Assembly:
Detailed procedures for putting components back together
Adjustment:
Carburetor synchronization, chain/belt tension (if applicable, VS750 has shaft drive), brake lever adjustment, clutch lever adjustment
Installation:
Procedures for installing new or repaired components
Technical Depth
Depth:
Comprehensive, step-by-step, bumper-to-bumper coverage
Diagrams And Illustrations:
Pictorial diagrams, exploded diagrams, drawings, photos, schematics
Special Tools:
Identification and usage of special service tools
Specifications And Data:
Service data, precautions, allowable limits, factory specifications, tightening torques
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
High resolution, fully printable
Binding Type
Binding:
Digital (PDF Download) - No physical binding
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, four-stroke, V-twin
Displacement:
747 cc (45.6 cu in)
Bore X Stroke:
See manual for exact specifications
Compression Ratio:
See manual for exact specifications
Valvetrain:
SOHC, 2 valves per cylinder
Performance
Horsepower:
Approx. 50-55 HP (varies by market and specific tuning)
Torque:
Approx. 60 Nm (varies by market and specific tuning)
Fuel System
Carburetion:
Dual Mikuni carburetors (specific model numbers to be found in manual)
Fuel Delivery:
Mechanical fuel pump
Lubrication System
Oil Type:
See manual for specific viscosity and API classification (e.g., SAE 20W-40 or 10W-40)
Oil Capacity:
See manual for specific capacity
🔧 Transmission
Standard
Type:
5-speed manual
Optional
Optional Type:
None
Features
Drive Type:
Shaft drive
Clutch:
Wet, multi-plate
📐 Dimensions
Exterior
Overall Length:
See manual for specific dimensions
Overall Width:
See manual for specific dimensions
Overall Height:
See manual for specific dimensions
Wheelbase:
See manual for specific dimensions
Weights
Dry Weight:
Approx. 200-210 kg (440-460 lbs)
Wet Weight:
See manual for specific weight with fluids
Fuel Capacity:
Approx. 13 Liters (3.4 US Gallons)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle)
Active Features
Braking System:
Disc front, drum or disc rear (depending on market and specific model variation - manual will clarify)
Lighting:
Headlight, taillight, turn signals
Passive Features
Frame Construction:
Steel cradle frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic Motorcycle)
Driver Assistance
Assistance Features:
N/A (Basic Motorcycle)
Connectivity
Connectivity Options:
N/A (Basic Motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
See manual for specific mileage/time intervals (typically 3,000-5,000 miles or 6-12 months)
Spark Plug Replacement:
See manual for specific mileage intervals
Air Filter Cleaning/Replacement:
See manual for specific mileage intervals
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for precise specification)
Coolant Type:
N/A (Air-cooled)
Final Drive Oil:
See manual for specific gear oil viscosity and type
Known Issues
Common Wear Items:
Clutch wear, carburetor performance degradation, voltage regulator issues (common on many bikes of this era), fork seal leaks
Maintenance Importance:
Following scheduled maintenance is crucial for reliability and longevity, especially concerning the lubrication and fuel systems.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Suzuki's history in motorcycle manufacturing, known for inline-fours and V-twins.
Model Evolution
Intruder Lineage:
The VS750 was a key model in establishing Suzuki's cruiser line, preceding larger displacement models.
Vs750 Introduction:
Introduced in the mid-1980s to compete in the popular cruiser market.
Production
Production Years:
1985-1991 (VS750), later succeeded by VS800
Manufacturing Locations:
Japan
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Suzuki VS750 was generally well-received for its styling and V-twin character within the cruiser market of its time.
Ratings
Owner Satisfaction:
Historically positive for its class, often praised for reliability and approachable performance.
Certifications
Safety Certifications:
N/A (Motorcycle safety is primarily governed by design and compliance with national standards)
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