Suzuki 1985-1997 VZ700 VS750 VS800 Intruder Repair Manual

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Type: Motorcycle

Vendor:

Sku: 145669

Tags: 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 Address Models Motorcycle Motorcycles Suzuki VS750 Intruder VS800 Intruder VZ700 Intruder

Product variants

Description

This manual covers the motorcycle models, including the VZ700, VS750, and VS800, for production years 1985 through 1997. Known for their V-twin engines and classic cruiser styling, these motorcycles offered a blend of performance and aesthetic appeal. The Intruder line established the brand as a significant player in the cruiser market, with models like the VS750 and VS800 appreciated for their reliability and distinctive character. These bikes are characterized by their liquid-cooled, 4-stroke V-twin engines, shaft drive, and wet, multi-plate clutches, providing a smooth and robust riding experience. This comprehensive service repair shop manual provides detailed information essential for the maintenance, repair, and troubleshooting of your motorcycle. It covers all major systems, including the engine, fuel system, transmission, electrical system, brakes, steering, and suspension. Within its pages, you will find factory-level detail on routine maintenance procedures, complete engine rebuilds, disassembly and assembly instructions, and diagnostic charts for resolving mechanical and electrical issues. This manual is an invaluable resource for owners, independent repair shops, and professional motorcycle technicians, enabling accurate and confident servicing.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Intruder

Motorcycle Models Covered:

VZ700, VS750, VS800

Production Years Covered:

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

Codes

Chassis Codes:

VZ700, VS750, VS800 (specific variations may exist)

👋 Introduction

Market Position

Target Audience:

Suzuki Intruder owners, independent repair shops, motorcycle technicians, and DIY enthusiasts seeking detailed service information.

Competitive Analysis

Value Proposition:

Provides authoritative, factory-authorized repair and maintenance procedures, enabling owners to perform tasks confidently and accurately, saving on dealership service costs.

Key Features

Manual Content Highlight:

Includes OEM specifications, torque values, electrical data, exploded diagrams, and step-by-step repair instructions.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, Maintenance, Service, Troubleshooting

Page Count

Estimated Page Count:

Varies by original factory publication, typically several hundred pages for comprehensive coverage.

Manual Type

Manual Type:

Service Repair Shop Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, diagnostics, tuning, rebuild procedures, including internal components.

Fuel System:

Carburetor(s) overhaul, adjustment, fuel pump, fuel lines, fuel tank maintenance.

Lubrication And Cooling:

Lubrication system operation, oil pump, oil filter, cooling system (if applicable, e.g., liquid-cooled variants), radiator, coolant.

Transmission Drive Chain:

Transmission internal components, clutch operation, gear shifting mechanisms, drive chain and sprockets maintenance and replacement.

Steering And Suspension:

Handlebar, fork assembly, steering head bearing maintenance, rear shock absorber service and adjustment.

Electrical System:

Wiring diagrams, ignition system, lighting, battery, charging system, starter motor, troubleshooting electrical faults.

Brakes:

Brake system maintenance, hydraulic fluid, caliper service, brake pad replacement, disc inspection.

Bodywork Frame:

Body panel removal and installation, frame inspection, mounting points.

Intake Exhaust:

Air filter service, exhaust system inspection and maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, fluid level checks, general lubrication.

Engine Rebuild:

Detailed step-by-step procedures for major engine overhauls, including piston, cylinder, valve train, and crankshaft service.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common and advanced mechanical and electrical issues.

Disassembly Assembly:

Comprehensive instructions for dismantling and reassembling various motorcycle components and systems.

Inspection Testing:

Procedures for inspecting parts for wear, damage, and proper function, including specific test methods.

Technical Depth

Depth Of Information:

Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Covers basic adjustments to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Printable pages for on-demand access to specific sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download - PDF)

Paper Type

Paper Type:

N/A (Digital Download - PDF)

Compatibility

Device Compatibility:

Compatible with all versions of Windows and Mac, smartphones, iPads, and other devices capable of opening PDF files.

Software Requirements

PDF Reader:

Adobe Acrobat Reader (free download available)

⚙️ Engine Specifications

Primary Engine Vz700

Engine Type:

Liquid-cooled, 4-stroke, V-twin

Displacement:

700 cc

Primary Engine Vs750

Engine Type:

Liquid-cooled, 4-stroke, V-twin

Displacement:

750 cc

Primary Engine Vs800

Engine Type:

Liquid-cooled, 4-stroke, V-twin

Displacement:

800 cc

Performance

Bore Stroke:

Specific values will be detailed in the manual for each model variant.

Compression Ratio:

Specific values will be detailed in the manual for each model variant.

Fuel System

Carburetion:

Typically Mikuni carburetors (specific models and sizes detailed in manual).

Fuel Delivery:

Mechanical fuel pump.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Shaft drive

📐 Dimensions

Exterior

Overall Length:

Varies by model and year, detailed in manual.

Overall Width:

Varies by model and year, detailed in manual.

Wheelbase:

Varies by model and year, detailed in manual.

Weights

Dry Weight:

Varies by model, approximately 450-480 lbs (204-218 kg).

Curb Weight:

Varies by model, approximately 480-510 lbs (218-231 kg).

🛡️ Safety Features

Ratings

Safety Certification:

Compliant with relevant motorcycle safety standards of the era.

Active Features

Braking System:

Front disc brake, rear drum or disc brake (depending on model variant).

Passive Features

Frame Construction:

Steel frame providing structural integrity.

💡 Technology Features

Infotainment

Infotainment Systems:

N/A (Standard motorcycle features of the era).

Driver Assistance

Assistance Features:

N/A (Standard motorcycle features of the era).

Connectivity

Connectivity Options:

N/A (Standard motorcycle features of the era).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual, typically every 3,000-5,000 miles or annually.

Valve Adjustment Interval:

Refer to manual, typically every 6,000-12,000 miles.

Fluid Specifications

Engine Oil Type:

API SE, SF, SG, SH or SJ, SAE 10W-40 or 20W-50 (check manual for specific viscosity based on temperature).

Brake Fluid Type:

DOT 3 or DOT 4 (check manual).

Coolant Type:

Ethylene glycol-based antifreeze (refer to manual for specific mixture ratio).

Known Issues

Carburetor Issues:

Carburetor clogging due to fuel varnish, requiring regular cleaning and stabilization.

Ignition Components:

Potential wear of spark plugs, ignition coils, or CDI unit over time.

Shaft Drive Maintenance:

Regular lubrication of the shaft drive is crucial to prevent wear.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long history of producing innovative and reliable motorcycles across various segments, from sportbikes to cruisers.

Model Evolution

Intruder Lineage:

The Intruder series was Suzuki's entry into the cruiser market, known for its V-twin engines and classic styling. The VS750 was a popular starting point, with the VS800 offering increased displacement and refinement.

Production

Manufacturing Location:

Primarily Japan.

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Intruder series was generally well-received for its styling and V-twin character, establishing Suzuki as a competitor in the cruiser market.