1990 Suzuki VS700 VS750 VS800 S50 Service Repair Manual Down

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Type: Motorcycle

Vendor:

Sku: 142970

Tags: 1990 Intruder Motorcycle Motorcycles S50 Suzuki VS700 VS750 VS800

Product variants

Description

This manual covers the VS700 Intruder, VS750 Intruder, VS800 Intruder, VS800GL Intruder, and S50 Boulevard motorcycles produced from 1989 through 1992, with extended coverage for the VS800 platform evolution into later S50 models. These motorcycles, powered by V-twin, four-stroke engines ranging from 699cc to 790cc, are known for their cruiser styling and reliable shaft drive. The Intruder series marked a significant entry into the cruiser market, with the VS800 platform evolving into the S50 Boulevard, offering a blend of classic design and dependable performance. This comprehensive Factory Service and Repair Manual provides detailed information essential for maintaining and repairing these motorcycles. It covers a wide array of systems including engine mechanicals, fuel, lubrication, cooling, ignition, electrical, transmission, shaft drive, chassis, braking, wheels, tires, and bodywork. Procedures for periodic maintenance, tune-ups, troubleshooting, and complete rebuilds are included, along with extensive diagrams, exploded views, and torque specifications. This resource is invaluable for owners, DIY enthusiasts, and professional mechanics seeking to ensure the longevity and optimal performance of their Intruder or Boulevard motorcycles.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VS700 Intruder / VS750 Intruder / VS800 Intruder / S50 Boulevard

Year:

1989, 1990, 1991, 1992

Model Codes:

VS700, VS750, VS800, S50

Generation

Intruder Generation:

First Generation (VS700/750/800 series)

👋 Introduction

Market Position

Target Audience:

Owners of Suzuki VS700, VS750, VS800 Intruder and S50 Boulevard motorcycles, DIY enthusiasts, independent mechanics, restoration specialists.

Competitive Analysis

Manual Value:

Provides factory-level repair information, crucial for maintaining and restoring these classic cruisers, often superior to aftermarket alternatives.

Key Features

Digital Delivery:

Instant download eliminates shipping costs and waiting time.

Completeness:

Factory-level detail ensures all aspects of maintenance and repair are covered.

📋 Manual Details

Coverage Areas

Covered Models:

Suzuki VS700 Intruder, VS750 Intruder, VS800 Intruder, VS800GL Intruder, S50 Boulevard (covering the VS800 platform evolution)

Covered Years:

1989, 1990, 1991, 1992 (and extended coverage for VS800 platform up to later years for S50)

Page Count

Estimated Pages:

Likely 300-600+ pages (typical for a comprehensive factory service manual)

Manual Type

Type:

Factory Service and Repair Manual

Language

Language:

English

Format

File Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul, valve timing, piston/ring inspection, cylinder bore, crankshaft, connecting rods, bearings.

Fuel System:

Carburetor removal, disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank maintenance.

Lubrication System:

Oil pump, oil filter, oil passages, lubrication schedules, oil pressure checks.

Cooling System:

Coolant type, capacities, radiator, hoses, thermostat, water pump, fan (if applicable).

Ignition System:

Ignition timing, spark plugs, ignition coils, CDI unit, electrical path diagnostics.

Electrical System:

Wiring diagrams, charging system (alternator, regulator/rectifier), battery, starting system (starter motor, solenoid), lighting, indicators, horn.

Transmission:

Gearbox disassembly, assembly, inspection, gear selection, lubrication.

Shaft Drive:

Rear drive unit disassembly, inspection, lubrication, U-joints, drive shaft maintenance.

Chassis Frame:

Frame inspection, geometry, front fork, rear shock absorber, swingarm maintenance.

Braking System:

Brake calipers, master cylinders, brake pads, brake fluid specifications, bleeding procedures, disc inspection.

Wheel Tires:

Wheel bearing inspection, tire pressure, tire replacement, wheel balancing.

Bodywork Trim:

Fender removal/installation, seat removal, tank removal, minor body panel adjustments.

Emission Control:

Emission control system components, troubleshooting (where applicable for the era).

Procedures Included

Periodic Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment (if applicable to older models or specific variants), brake checks, tire pressure checks.

Tune Up:

Carburetor synchronization, idle speed adjustment, ignition timing checks, valve clearance adjustment.

Troubleshooting:

Diagnostic flowcharts, common problems and solutions, electrical system troubleshooting.

Rebuild Overhaul:

Detailed instructions for engine, transmission, and drive unit rebuilding.

Wiring Schematics:

Complete electrical system wiring diagrams for accurate diagnosis and repair.

Part Numbers:

Likely includes reference numbers for key components, aiding in parts sourcing.

Technical Depth

Depth:

Comprehensive, from basic owner maintenance to advanced mechanical and electrical repairs, including full engine and transmission rebuilds.

Illustrations:

Extensive diagrams, exploded views, and illustrations for clear guidance.

Specifications:

Includes detailed torque specifications, clearances, fluid capacities, and performance data.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF (depending on scan quality)

Print Quality

Printability:

Yes, printable

Binding Type

Digital Format:

Downloadable digital file

Paper Type

Physical Format:

N/A (Digital Delivery)

Compatibility

Operating Systems:

Windows and MAC

Requirements

Software:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Type:

V-Twin, Four-Stroke

Displacement Vs700:

699 cc (approx.)

Displacement Vs750:

747 cc (approx.)

Displacement Vs800 S50:

790 cc (approx.)

Cooling:

Liquid-cooled

Performance

Horsepower Vs700 Approx:

50-55 HP

Torque Vs700 Approx:

45-50 lb-ft

Horsepower Vs800 Approx:

53-57 HP

Torque Vs800 Approx:

50-55 lb-ft

Fuel System

Carburetion:

Dual Mikuni carburetors (e.g., VM34 or similar)

Fuel Type:

Unleaded gasoline

Engine Internals

Bore X Stroke Vs700:

70.0 mm x 72.0 mm (approx.)

Bore X Stroke Vs800:

83.0 mm x 74.4 mm (approx.)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Final Drive:

Shaft drive

Fluid Specifications

Transmission Oil Type:

API GL-4 Hypoid gear oil, SAE 80W-90 (Verify with specific manual for exact spec)

📐 Dimensions

Exterior

Wheelbase Vs800 Approx:

1595 mm (62.8 in)

Weights

Dry Weight Vs800 Approx:

208 kg (459 lbs)

💡 Technology Features

Infotainment

Features:

Basic analog gauges (speedometer, tachometer, fuel gauge, indicator lights). No modern infotainment systems.

Driver Assistance

Features:

No electronic driver assistance systems; focus is on mechanical and rider input.

Connectivity

Features:

No connectivity features.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 km (1,800-3,000 miles) or annually (check manual for exact interval).

Spark Plug Replacement:

Typically every 10,000-20,000 km (6,000-12,000 miles), inspect at 5,000 km intervals.

Valve Clearance Check:

Initial check at 1,000 km, then every 10,000-20,000 km (check manual).

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 or 10W-50 motorcycle oil (Verify with specific manual for exact spec).

Engine Oil Capacity Vs800 Approx:

2.7 Liters (2.9 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4 (Verify with specific manual for exact spec)

Known Issues

Carburetor Issues:

Carburetors can become clogged with age, leading to hard starting, rough idle, or poor performance. Diaphragms can also degrade.

Charging System Issues:

Stator windings and regulator/rectifiers can be prone to failure over time, leading to battery charging problems.

Shaft Drive Lubrication:

Regular inspection and lubrication of the shaft drive are critical to prevent wear.

Cooling System Leaks:

Hoses and seals can degrade, leading to coolant leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Model Evolution

Intruder Launch:

The Intruder line was Suzuki's entry into the cruiser market, with the VS700/750 being among the first models, evolving into the VS800 and later the S50 Boulevard.

S50 Transition:

The S50 Boulevard is essentially an updated VS800 Intruder, featuring styling refinements and modernizations, but retaining the core chassis and engine platform.

Production

Production Period:

VS700/750 Intruder (mid-late 1980s), VS800 Intruder (late 1980s - early 2000s), S50 Boulevard (early 2000s - 2009).