1987-2004 Suzuki VS1400 Intruder Service Manual

Wiring diagrams, specifications, and repair sequences for the Suzuki VS1400 Intruder. Includes part numbers and detailed procedures. Publication 99500-39156-03E.

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Document Details

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Document Number / Seller:
26485 / Thomas Thompson
File Size:
37.82 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Jun 30, 2025

Models Covered & Key Technical Specifications

Suzuki VS1400 (99500-39156-03E) - 1987-2004 Shop-grade manual for Suzuki VS1400 Intruder, 1987-04 Information-Suite | Series Volume.

  • Measured Current Rating: 10A protects the main electrical circuit from overload.
  • Established Climate Specs: For optimal operation, 0-32°C (32-90°F) defines the ideal environmental range.
  • Factory Output Performance: 12.5 PS signifies the maximum engine power output.
  • Integral Assembly Torques: The engine mounting bolts require 50-65 N·m for secure installation.
  • Operational Net Mass: For optimal balance, 175 kg (385 lbs) is the target vehicle weight.
  • Critical Wattage Specs: The ignition coil produces a high-voltage spark for reliable combustion.

Professional Workshop Service Manual & Technical Specifications

Essential Performance Parts Manual: Suzuki VS1400 Intruder Service Manual: 1987-2004 Information-Suite

Year-Coverage: 1987-2004 // Assembly-Group: Engine / Shaft Drive Logic // Year-Coverage: Reference Data.

Technical Specs Table

Integrated-Framework Diagnostic-Logic Calibration-Data
Engine Specifications Electrical System Fuel and Lubrication System
Chassis Details Emission Control Shaft Drive System
Periodic Maintenance General Information Appendix

Providing a structural breakdown of the Suzuki VS1400 Intruder, this manual details its intricate systems, from engine assembly to electrical troubleshooting. Careful inspection of components is documented, enabling users to understand the motorcycle's function.

Troubleshooting Procedures

The troubleshooting chapter addresses common issues with the VS1400 Intruder, providing guidance for diagnosis and repair.

Cooling System Maintenance

Cooling system maintenance is addressed in the fuel and lubrication section, outlining necessary checks and procedures.

Testing Requirements

Testing requirements are specified for the electrical system, including charging and ignition tests.

Clearance Measurements

Clearance measurements are addressed for critical engine components like pistons and valves.

Special Procedures

Special procedures are addressed for tasks such as carburetor balancing and drive shaft maintenance.

This manual documents torque specifications for engine and chassis components to ensure proper pressure slip prevention.

FAQ

Reference the **specified** tool requirements for drive shaft maintenance. keyboard_arrow_down

A 22 mm long socket (part number 09924-64510) is required for the final drive gear nut. A special tool (09900-06108) is needed to remove the circlip from the propeller shaft.

What are the **essential** electrical values for the starter motor? keyboard_arrow_down

9 mm (0.35 in) is the service limit for the starter motor brush length. The commutator under-cut service limit is 0.2 mm (0.008 in).

Specify the **correct** calibration settings for the carburetors. keyboard_arrow_down

The float height for the No. 1 (Rear) carburetor is 27.7 ± 0.5 mm (1.09 ± 0.02 in), and for the No. 2 (Front) carburetor is 9.1 ± 0.5 mm (0.36 ± 0.02 in). Page 5-19 details these adjustments.

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Reviews (4)

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This manual has all the information you need for servicing your bike. I appreciated the fast download link and the professional support I received when I had questions.
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Rated 5 out of 5 stars
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This service manual is a must-have for any VS1400 owner. The detailed sections and clear instructions made my maintenance so much easier. Plus, the download process was a breeze!
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I found this manual incredibly useful for my Suzuki Intruder. It covers everything comprehensively and the customer support was excellent—quick email responses!