Suzuki Intruder VS700, VS750, VS800, Boulevard VS800/S50 Repair Manual 1985-2007

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Item # M481-5  ISBN: 9781599691756




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This repair manual covers Suzuki Intruder models including,

• VS700 1985-1987 (US)
• VS750 1988-1991 (US), 1985-1991 (UK)
• VS800 1992-2004 (US), 1992-1997 (UK)
• Boulevard S50 (VS800/S50) 2005-2007

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Service hints | Torque specifications | Fasteners | Lubricants | RTV gasket sealant | Threadlock | Gasket remover | Expendable supplies | Basic hand tools | Precision measuring tools | Special tools | Cleaning solvent | Mechanic's tips | Ball bearing replacement | Oil seals | Riding safety

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Troubleshooting instruments | Troubleshooting | Engine performance | Engine noises | Engine lubrication | Clutch | Transmission | Excessive vibration | Carburetor troubleshooting | Front suspension and steering | Brake problems

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Routine checks | Pre-checks | Service intervals | Tires and wheels | Battery | New battery installation | Battery electrical cable connectors | Periodic lubrication | Periodic maintenance | Tune-up

CHAPTER FOUR: ENGINE
Engine principles | Serving engine in frame | Engine | Front cylinder head cover and camshaft | Rear cylinder head cover and camshaft | Camshaft | Cylinder head and cylinder | Valves and valve components | Pistons and piston rings | Oil pump | Primary drive gear | Secondary gear assembly | Crankcase | Crankshaft and connecting rods | Break-in

CHAPTER FIVE: CLUTCH
Clutch | Clutch hydraulic system | Master cylinder | Slave cylinder | Bleeding the system

CHAPTER SIX: TRANSMISSION and GEARSHIFT MECHANISMS
External gearshift mechanisms | Transmission

CHAPTER SEVEN: FUEL, EMISSION CONTROL and EXHAUST SYSTEMS
Carburetor operation | Carburetor service | Carburetor assembly | Carburetor service | Carburetor adjustments | Throttle cable replacement | Fuel tank | Fuel shutoff valve and filter | Fuel pump | Crankcase breather system (U.S. only)? | Evaporative emission control system (California models only)? | Exhaust system

CHAPTER EIGHT: ELECTRICAL SYSTEM
Electrical connectors | Battery negative terminal | Charging system | Voltage regulator/rectifier | Alternator | Transistorized ignition system | Starter system | Electric starter | Starter clutch and gears | Starter relay | Lighting system | Switches | Electrical components | Fuses | Circuit breaker | Wiring diagrams

CHAPTER NINE: LIQUID COOLING SYSTEM
Hoses and hose clamps | Cooling system check | Pressure check | Cooling fan, shroud and fan duct | Thermostat and housing | Water pump | Hoses

CHAPTER TEN: FRONT SUSPENSION and STEERING
Front hub | Wheels | Tire changing | Tire repairs | Handlebar | Steering head and stem | Front fork

CHAPTER ELEVEN: REAR SUSPENSION and FINAL DRIVE
Rear wheel | Rear hub | Final drive unit, drive shaft and universal joint | Swing arm | Shock absorbers

CHAPTER TWELVE: BRAKES
Disc brakes | Front brake pad replacement | Front brake caliper | Front brake hose replacement | Front brake disc | Bleeding the system | Rear drum brake | Rear brake pedal and linkage

CHAPTER THIRTEEN: BODY and FRAME
Seats | Frame side covers | Frame head side covers | Footpegs | Sidestand | Front fender | Frame

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Suzuki Intruder VS700, VS750, VS800, Boulevard VS800/S50 Repair Manual 1985-2007