1986-1988 Suzuki VS700 Intruder Motorcycle Repair Manual

Description

This 348 page, 1986-1988 Suzuki VS700 Intruder motorcycle Repair Manual is a reproduction of the original out of print manual. This manual includes the required supplements for additional years. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following motorcycles:

1986 Suzuki VS700GLF Intruder
1986 Suzuki VS700GLP Intruder
1987 Suzuki VS700GEF Intruder (supplement 99501-36040-03E)
1987 Suzuki VS700GEP Intruder (supplement 99501-36040-03E)
1987 Suzuki VS700GLH Intruder (supplement 99501-36060-03E)
1988 Suzuki VS750GLJ Intruder (supplement 99501-37100-03E)

The Suzuki VS700 is more commonly known by its marketing name, the Suzuki Intruder 700. It was part of the Intruder series, introduced in the mid-1980s as Suzuki’s response to the popularity of cruiser-style motorcycles in the U.S. The VS700 was specifically produced to comply with a tariff on imported motorcycles over 700cc at the time. With a V-twin engine and a classic cruiser design, it competed with other popular cruiser models of that era.

The Suzuki VS700GL has been developed as a new generation motorcycle. It is packed with highly advanced design concepts, including a V-2 engine, a liquid cooling system, a new highly efficient combustion system (TSCC), a fully transistorized ignition system, and a shaft drive mechanism. Combined with precise control and easy handling, the VS700GL provides excellent performance and outstanding riding comfort.

This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair, and service Suzuki motorcycles. Apprentice mechanics and do-it-yourself mechanics will also find this manual an extremely useful repair guide.

Table of Contents
General Information
Serial Number Locations
Fuel, Oil and Coolant
Recommendations
Breaking-In Procedures
Cylinder Identification
Special Materials
Precautions and General Instructions
Specifications

Periodic Maintenance And Tune-Up Procedures
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Point
Maintenance and Tune-Up Procedures
Battery
Air Cleaner
Valve Clearance
Sparkplug
Engine Oil and Oil Filter
Carburetor
Fuel and Vapor Hoses
Clutch
Cooling System
Final Gear Oil
Brakes
Tires
Steering
Front Fork
Chassis Bolts and Nuts

Engine
Compression Check
Engine Components Removable With the Engine in Place
Engine Removal and Reinstallation
Engine Removal
Engine Reinstallation
Engine Disassembly
Engine Components Inspection and Servicing
Cylinder Head Cover
Cylinder Head
Cylinder
Piston
Piston Ring
Piston Pin and Pin Bore
Connecting Rod
Crankshaft
Clutch
Generator and Signal Generator
Oil Pump
Transmission
Engine Reassembly
Camshaft Timing
Valve Rocker Arm and Shaft

Shaft Drive
Secondary Bevel Gears Construction
Removal and Disassembly
Inspection
Reassembly
Secondary Gears Shim Adjustment
Backlash
Tooth Contact
Final Assembly and Remounting
Reassembly Information
Final Bevel Gears Construction,
Final Gear Case Breather Circuit
Removal and Disassembly
Inspection
Reassembly
Final Gear Shim Adjustment
Final Gear Bearing Case Shim Clearance
Backlash
Tooth Contact
Reassembly Information

Cooling System
Cooling Solution
Radiator and Water Hoses
Thermostat
Water Pump
Thermo-Switch
Engine Thermo-Switch
Fan Motor

Fuel and Lubrication System
Fuel System
Fuel Cock
Fuel Pump
Fuel Pump Relay
Carburetor
Carburetor Construction
Specifications
I.D. No. Location
Diaphragm and Piston Operation
Slow System
Transient Enrichment System
Main System
Starter System
Float System
Disassembly
Needle Valve Inspection
Float Height Adjustment
Reassembly
Fuel Level Inspection
Balancing Carburetors
Lubrication System
Oil Pressure
Oil Sump Filter
Lubrication System Chart

Emission Control Information
Emission Control Carburetor Components

Electrical System
Charging System
Ignition System
Starter System
Speedometer And Instrument Panel
Water Temperature Unit And Indicator Lamps
Switches
Battery

Chassis
Front Wheel
Front Brake
Front Fork
Steering Stem
Rear Wheel And Brake
Rear Suspension And Swing Arm
Clutch Master Cylinder

Servicing Information
Troubleshooting
Wiring Diagram
Cable, Harness And Hose Routing
Special Tools
Tightening Torque
Service Data