This manual covers the VS700, VS750, VS800 Intruder, and S50 Boulevard cruiser motorcycles, produced primarily from the mid-1980s through the 1990s, with the S50 representing a later evolution of this platform. These motorcycles are powered by liquid-cooled, 4-stroke V-twin engines ranging from 700cc to 805cc, featuring shaft drive and 5-speed transmissions. Known for their classic cruiser styling and reliable V-twin performance, the Intruder series established a strong presence in this segment. This factory service repair manual provides essential information for maintaining the engineering quality and unique character of these vehicles.
This comprehensive English-language manual serves as an indispensable resource for owners, mechanics, and technicians. It details a wide array of maintenance and repair procedures, including engine, fuel system, lubrication, cooling, shaft drive, electrical, and chassis systems. The manual offers step-by-step instructions, exploded diagrams, wiring schematics, and detailed specifications necessary for routine maintenance, tune-ups, troubleshooting, and complete overhauls. It is designed to facilitate the proper upkeep and repair of your VS/S50 motorcycle, ensuring its longevity and optimal performance.
Model:
VS700 Intruder / VS750 Intruder / VS800 Intruder / S50 Boulevard
Year:
1985-1988 (for VS700, VS750, VS800), with implied coverage for S50 which succeeded these models.
Vehicle Type:
Cruiser Motorcycle
Chassis Code:
VS700, VS750, VS800 (S50 designation primarily for later models, but manual covers the foundational platform).
Generation:
First Generation Intruder platform.
Market Position:
Essential resource for owners and mechanics of early Suzuki Intruder cruisers, bridging the gap to the S50 Boulevard designation.
Competitive Analysis:
Provides factory-level detail often surpassing aftermarket manuals, crucial for maintaining the unique engineering of these Suzuki V-twins.
Key Features:
Factory-level accuracy, extensive diagrams, wiring schematics, step-by-step procedures, instant download convenience.
Target Audience:
Do-it-yourself mechanics, vintage motorcycle enthusiasts, customizers, and professional motorcycle repair technicians.
Coverage Areas:
Comprehensive repair and maintenance for the specified Suzuki VS/S50 motorcycle series.
Page Count:
Undisclosed (Typical for factory service manuals to be extensive, likely 300+ pages).
Manual Type:
Factory Service Repair Manual.
Systems Covered:
Engine, Fuel System, Lubrication System, Cooling System, Shaft Drive, Electrical System, Chassis, Emission Control Systems.
Electrical System Details:
Complete wiring schematics, lighting system, ignition system, charging system, starter system, instrument panel.
Chassis Details:
Front fork service, rear suspension, wheel bearings, steering system, brake system overhaul, frame inspection.
Procedures Included:
Routine maintenance, tune-up, troubleshooting, complete repair, rebuilding, refurbishment, restoration procedures.
Troubleshooting Guidelines:
Systematic troubleshooting charts and flowcharts for diagnosing common problems.
Tune Up Procedures:
Detailed steps for valve clearance adjustment, ignition timing checks, carburetor adjustments, and general engine tuning.
Technical Depth:
Detailed step-by-step instructions, exploded diagrams, wiring schematics, specifications, suitable for DIY and professional mechanics.
Searchability:
PDF format typically allows for text searching, significantly aiding in locating specific information.
Print Quality:
Printable (High-resolution, suitable for clear reproduction).
Binding Type:
Digital Download (No physical binding).
Paper Type:
N/A (Digital format).
Engine Type:
Liquid-cooled, 4-stroke, V-twin.
Engine Displacement:
700cc (VS700), 750cc (VS750), 805cc (VS800/S50).
Bore X Stroke:
VS700: 70.0 mm x 77.0 mm; VS750: 75.0 mm x 77.0 mm; VS800: 83.0 mm x 74.4 mm.
Horsepower:
Varies by model and year, typically in the 45-55 HP range at peak.
Torque:
Varies by model and year, typically in the 50-60 lb-ft range.
Fuel Delivery:
Carbureted (Dual Mikuni carburetors, specific models vary).
Carburetor Size:
Typically 34mm or 36mm Mikuni constant velocity carburetors.
Valve Train:
SOHC, 4 valves per cylinder (3 valves for some early VS700/VS750 configurations).
Ignition System:
Electronic ignition (CDI).
Compression Ratio:
Approximately 9.3:1 to 10.0:1 (varies by specific model and year). Refer to manual for exact figures.
Oil Type Spec:
Suzuki recommends API SE, SF or SG classification oil, SAE 10W-40 viscosity. (Refer to manual for exact specifications).
Oil Capacity:
Approximately 2.5 - 3.0 liters with filter change. (Refer to manual for exact capacities).
Transmission Type:
5-speed constant mesh sequential manual.
Optional Transmission:
N/A
Final Drive:
Shaft Drive.
Clutch Type:
Wet multi-plate.
Length:
Varies by model, approximately 2300-2400 mm.
Width:
Varies by model, approximately 800-850 mm.
Height:
Varies by model, approximately 1100-1200 mm.
Wheelbase:
Approximately 1600 mm.
Dry Weight:
Approximately 180-200 kg.
Gross Vehicle Weight Rating:
N/A (Motorcycle specific).
Fuel Tank Capacity:
Approximately 12-15 liters.
Safety Ratings:
N/A (Motorcycle safety is assessed differently than cars).
Active Features:
Hydraulic disc brakes (front and rear).
Brake Specifications Front:
Single disc, hydraulic, often with dual-piston calipers.
Brake Specifications Rear:
Single disc, hydraulic, often with single-piston calipers.
Passive Features:
Sturdy frame construction, rider ergonomics.
Infotainment System:
N/A (Basic motorcycle instrumentation).
Driver Assistance Features:
N/A
Connectivity Options:
N/A
Diagnostic Tools Coverage:
Manual provides diagnostic procedures for electrical systems, engine performance, and chassis components, enabling troubleshooting without specialized electronic tools.
Engine Oil Change:
Every 3,000-5,000 km or annually. (Refer to manual for precise interval).
Spark Plug Replacement:
Every 10,000-15,000 km. (Refer to manual for specific plug type and gap).
Air Filter Cleaning Replacement:
Check every 5,000 km, clean or replace as needed. (Refer to manual).
Shaft Drive Maintenance:
Check/change final drive oil every 10,000-15,000 km. (Refer to manual for fluid type and capacity).
Coolant Type:
Permanent type antifreeze (ethylene glycol-based), Suzuki recommends a 50/50 mix with distilled water. (Refer to manual).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Final Drive Oil Type:
Gear oil, SAE 80 or 90 GL-5. (Refer to manual for specific recommendations).
Known Issues:
Carburetor synchronization can drift, leading to rough idling or poor throttle response. Cam chain tensioners may require adjustment or replacement over time. Ignition system components (coils, pickups) can degrade. Shaft drive spline lubrication is critical to prevent wear.
Common Repairs:
Carburetor rebuilds/cleaning, spark plug replacement, air filter replacement, brake fluid flush, shaft drive lubrication.
Brand Heritage:
Suzuki has a long history of producing reliable and innovative motorcycles, particularly in the V-twin cruiser segment with the Intruder line.
Model Evolution:
The VS700/750/800 Intruder series established Suzuki's presence in the cruiser market, evolving into the Boulevard S50, known for its classic styling and V-twin character.
Production Years:
VS700/750/800: Mid-1980s through the 1990s; S50: Mid-2000s.
Manufacturing Locations:
Japan.
Recognitions:
N/A (Specific awards for this early model series are not readily documented in general reviews, but the Intruder line was well-received for its styling and value).
