1986-1992 Suzuki VS750GL / VS800GL Service Manual (408 Pages)

Technical Scope and Service Documentation for 1986–1992 Suzuki VS750GL and VS800GL

• Covers 1986–1992 Suzuki VS750GL and VS800GL V-twin cruisers, documenting maintenance and engine rebuild specs for all annual variants from GLG through GLN
• Official OEM publication P/N 99500-37047-01E, Motorcycle Technical Service Department
• Contains 408 pages of technical reference, including extensive torque specification tables, exploded-view schematics for engine/chassis systems, and maintenance interval charts
• File link appears in your order confirmation straight away
• Suitable for printing individual sections for shop-floor use
• Indexed PDF search covers every chapter and appendix
• This specific edition captures the complete production run of the 750cc displacement and the transition to the 800cc build

Document Structure and Technical Reference

Engine and Chassis Walkthrough

This manual provides an exhaustive examination of the V-twin powertrain, detailing disassembly and reassembly protocols for the crankshaft, transmission, and cooling systems. The text focuses on component inspection, listing wear limits for pistons, rings, camshafts, and valve seats. Separate sections document the chassis, covering suspension, steering, and braking components with high-level technical clarity. Maintenance schedules are clearly outlined, providing interval tables for routine lubrication, fluid exchanges, and component adjustments across the entire product life cycle.

Specification and Reference Data

Technical data is provided in comprehensive tables, such as the torque values for chassis bolts, engine mounting points, and internal assemblies. Cylinder head bolt torque values are documented in a multi-stage sequence in the engine assembly data. The cooling system capacity for the VS750GL is documented at 1.7 liters. Intake valve clearance is listed at 0.08–0.13 mm in the cylinder head specification table. Detailed material lists for sealants and locking agents are included to ensure precise assembly. This document acts as an official Suzuki OEM service publication for the 1986–1992 VS750GL and VS800GL, providing critical technical data for the maintenance, engine rebuild, and chassis service of these liquid-cooled V-twin cruiser motorcycles.