Suzuki VS700 VS800 INTRUDER Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Intruder VS700 / VS800 Model Aliases: Suzuki Boulevard S50 (VS800) Generation Production Years: VS700: 1986-1987, VS800: 1987-2004 (US market, continued as Boulevard S50...

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类型: Motorcycle

斯库: 406915

标签: INTRUDER Motorcycle Motorcycles Suzuki VS700 VS800

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Intruder VS700 / VS800

Model Aliases:

Suzuki Boulevard S50 (VS800)

Generation

Production Years:

VS700: 1986-1987, VS800: 1987-2004 (US market, continued as Boulevard S50 until 2009)

👋 Introduction

Market Position

Category:

Cruiser Motorcycle

Target Audience:

Owners and independent mechanics seeking to maintain, repair, and troubleshoot Suzuki VS700/VS800 Intruder motorcycles.

Competitive Analysis

Competitors:

Honda Shadow, Yamaha Virago, Kawasaki Vulcan, Harley-Davidson Sportster.

Key Features

Design:

Classic cruiser styling, V-twin engine, shaft drive, comfortable riding position.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF), potentially Print

Page Count:

Estimated 300-500 pages (typical for this era of motorcycle service manuals)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, lubrication, cooling system, fuel system (carburetor tuning, jetting, fuel pump), ignition system, exhaust system.

Transmission:

Gearbox removal, disassembly, inspection, assembly, shift mechanism, final drive (shaft drive).

Chassis Suspension:

Front fork (disassembly, seals, oil, springs), rear shock absorber (removal, inspection), swingarm, bearings.

Brakes:

Front and rear brake systems, hydraulic circuits, caliper service, master cylinder, brake fluid replacement, bleeding procedures, pad and disc inspection/replacement.

Electrical System:

Wiring diagrams, lighting (headlight, taillight, turn signals), battery, charging system (stator, rectifier/regulator), ignition coils, starter motor, switches, fuses, diagnostic codes (if applicable).

Fuel System:

Carburetor operation, disassembly, cleaning, reassembly, jetting specifications, fuel tank, fuel lines, fuel pump (VS800).

Bodywork Frame:

Frame inspection, body panels, fenders, seat, fuel tank removal/installation, controls (handlebars, levers, cables).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, chain/drive inspection, brake fluid flush, coolant service (if applicable).

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical system diagnosis.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation. Includes engine, transmission, suspension, brakes, electrical components, and bodywork.

Specifications:

Torque values for critical fasteners, engine clearances, fluid capacities, part numbers, electrical specifications, maintenance intervals.

Technical Depth

Scope:

Comprehensive coverage from basic rider maintenance to complete engine and transmission rebuilds. Includes detailed diagrams and schematics.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - typically searchable and printable.

Print Quality

Illustrations:

High-quality diagrams, exploded views, and photographs to illustrate procedures.

Binding Type

Physical Format If Applicable:

Perfect bound or spiral bound (for printed versions) for ease of use on a workbench.

Paper Type

Physical Format If Applicable:

Durable paper stock to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke, SOHC, 4 valves per cylinder (2 per cylinder for VS700/VS800)

Displacement:

VS700: 699 cc (42.6 cu in); VS800: 805 cc (49.1 cu in)

Bore X Stroke:

VS700: 79.0 mm x 71.0 mm (3.11 x 2.80 in); VS800: 83.0 mm x 74.4 mm (3.27 x 2.93 in)

Compression Ratio:

Typically around 9.2:1 to 9.6:1 (check specific model year)

Cooling System:

Liquid-cooled

Performance

Horsepower:

VS700: Approx. 60-65 HP; VS800: Approx. 65-70 HP (wheel horsepower will vary)

Torque:

VS700: Approx. 45-50 lb-ft; VS800: Approx. 50-55 lb-ft

Fuel System

Carburetion:

Dual Mikuni carburetors (e.g., VM34SS for VS700, BSR36 for VS800)

Fuel Tank Capacity:

Approx. 11-13 liters (2.9-3.4 US gal)

Lubrication

Oil Type:

SAE 10W-40 motorcycle-specific engine oil (API SG or higher, JASO MA compliant)

Oil Capacity:

Approx. 2.5-3.0 liters (2.6-3.2 US qt) with filter change

Ignition

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Spark Plugs:

NGK CR9E or similar (verify specific plug for model year)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Drive Type:

Shaft drive

Features

Clutch Type:

Wet multi-plate

Transmission Oil Type:

SAE 80W-90 hypoid gear oil (or specified gear oil)

Transmission Oil Capacity:

Approx. 0.9-1.1 liters (0.95-1.16 US qt)

📐 Dimensions

Exterior

Length:

Approx. 2200-2300 mm (86.6-90.6 in)

Width:

Approx. 800-850 mm (31.5-33.5 in)

Height:

Approx. 1150-1200 mm (45.3-47.2 in)

Wheelbase:

Approx. 1590-1600 mm (62.6-63.0 in)

Weights

Dry Weight:

VS700: Approx. 180-190 kg (397-419 lbs); VS800: Approx. 190-200 kg (419-441 lbs)

Curb Weight:

Approx. 200-220 kg (441-485 lbs) with fluids

Weight Distribution:

Designed for stable handling, typically around 50/50 when rider is seated.

🛡️ Safety Features

Ratings

Crash Safety:

As with most motorcycles, safety depends heavily on rider skill and protective gear. No standardized crash ratings like cars.

Active Features

Braking System:

Disc brakes front and rear. Early models may have drum rear brake. ABS was not commonly available.

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Passive Features

Frame Construction:

Steel frame, designed for rigidity and rider support.

Tires:

Tubeless tires. Common sizes include 100/90-19 front and 150/80-15 rear (verify specific sizes).

💡 Technology Features

Infotainment

Audio System:

None (classic cruiser design, no integrated audio).

Instrumentation:

Analog speedometer, tachometer (on some models), odometer, trip meter, indicator lights for turn signals, high beam, oil pressure, neutral.

Driver Assistance

Not available on most models. Later Boulevard S50 models might have offered it as an option in some markets, but it was rare.

Connectivity

Bluetooth Usb:

Not available (classic motorcycle technology).

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 3,000-5,000 miles or 6-12 months, whichever comes first. Consult manual for exact interval.

Spark Plugs:

Inspect every 7,500 miles, replace as needed. Rebuild kits for carburetors are common maintenance items.

Brake Fluid:

Flush and replace every 2 years or as recommended.

Final Drive Oil:

Change every 10,000-15,000 miles or annually. Inspect gaiter for leaks.

Fluid Specifications

Engine Oil Viscosity:

10W-40 Motorcycle Oil (JASO MA)

Cooling System Coolant:

Ethylene glycol-based coolant, 50/50 mix with distilled water (Suzuki recommends specific coolant).

Brake Fluid Type:

DOT 4.

Known Issues

Carburetor Issues:

Pilot jets can become clogged, leading to hard starting or poor idle. Diaphragms can crack or tear over time.

Electrical Connections:

Corrosion on electrical connectors can cause intermittent faults, especially in humid climates. Check grounds.

Fuel Pump Reliability:

Early VS700 models did not have a fuel pump; VS800 models have one which can be a point of failure if not maintained. Diaphragm issues are common.

Stator And Rectifier:

Charging system components can fail over time, leading to battery drain. Regular checks of voltage output are advisable.

Front Fork Seals:

Fork seal leaks are common with age and mileage. Regular inspection and replacement are recommended.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, a Japanese multinational corporation renowned for its wide range of products, including motorcycles, automobiles, ATVs, and marine engines.

Model Evolution

Genesis:

The VS700 Intruder was introduced in 1986 as Suzuki's entry into the burgeoning cruiser market, competing with American and Japanese rivals. It featured a distinctive V-twin engine and shaft drive.

Evolution To Vs800:

In 1987, Suzuki increased the displacement to 805cc (VS800) to provide more power and torque, addressing a common desire in the cruiser segment. This engine became the mainstay for many years.

Rebranding:

In 2005, the VS800 Intruder was re-badged as the Suzuki Boulevard S50, continuing with the same core platform but with updated styling and branding as part of Suzuki's broader Boulevard cruiser line-up.

Production

Manufacturing Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Consumer Reviews:

Generally well-regarded for its reliable V-twin engine, comfortable ride, and value for money in the cruiser segment.

Industry Awards:

While specific industry awards for these models are not widely publicized, they were consistently popular entries in the mid-size cruiser class throughout their production runs.

Ratings

Reliability:

High reliability rating when properly maintained, known for durable powertrains.