1986-1987 Suzuki VS700GL, VS750GL, VS800GL Service & Repair Manual (P/N 99500-38029-03E)
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Suzuki Models Covered & Key Technical Specifications
Models: Suzuki VS700GL, VS750GL, VS800GL
Sub-models / Variants: GLF, GLP, VS700GLE, VS700GLH, VS750GLJ, VS750GLK, VS750GLFL, VS750GLPL, VS750GLFM, VS750GLPM, VS800GLN, VS800GLP, VS800GLR, VS800GLS, VS800GLT, VS800GLV, VS800GLW, VS800GLX, VS800GLY, VS800K1, VS800K2, VS800K3, VS800K4
Trade Names: Intruder
Model Years: 1986–2004
Serial Numbers: V.I.N. stamped on steering head pipe, Engine serial number stamped on right rear of crankcase
Technical Data:
- Engine type: Four-stroke, water-cooled, OHC, 45-degree V-twin
- Piston displacement: 699 cc
- Bore x Stroke: 80.0 mm x 69.6 mm
- Compression ratio: 10.0:1
- Idle speed: 1000 ± 100 r/min
- Transmission: 5-speed constant mesh
- Final drive: Shaft drive
- Front suspension: Telescopic, coil spring, oil damped
- Rear suspension: Swinging arm, 5-way adjustable spring pre-load
- Front tire: 100/90–19 57H
- Rear tire: 140/90–15 70H
Suzuki Manual Features & Content Preview
- Covers 1986–2004 Suzuki VS700GL, VS750GL, and VS800GL Intruder motorcycles, documenting factory service, engine assembly, and chassis maintenance requirements
- Official Suzuki Motor Corporation publication P/N 99500-38029-03E, 1990 edition
- Contains 22 detailed group index sections including specialized coverage for engine overhaul, shaft drive, and emission control components
- Delivers 242 pages of technical data, exploded-view schematics, and torque specifications for professional shop use
- Provides the foundational service data for the long-running Intruder V-twin series, including transitional mechanical notes for GLF and GLP configurations
Manual Structure and Content
This factory service publication provides technical documentation for the Intruder series. Coverage spans fundamental maintenance for V-twin engine internals, shaft drive mechanisms, and liquid cooling systems. Maintenance procedures are organized into logical groups, detailing routine inspection intervals for fluid systems, electrical components, and chassis adjustments. The text incorporates specific tolerances for valve clearance, compression check values, and piston ring end-gap data to support high-precision work. Working on high-pressure fluid systems or heavy engine components carries inherent risks; always verify local safety protocols and utilize proper lifting equipment before beginning any maintenance task.
Specification and Reference Data
Engine compression for the Suzuki VS700GL is documented at 1300–1600 kPa (184–227 psi) in the diagnostic tables. Intake and exhaust valve clearance is specified at 0.08–0.13 mm for cold engines. The front brake system requires DOT 3 or DOT 4 fluid as noted in the service safety sections. Cylinder head cover bolt torque is strictly listed at 21–25 N.m for 140 mm bolts in the engine assembly section. This technical guide serves as an authoritative reference point for any shop executing a complex repair, ensuring precise mechanical breakdowns for all chassis and electrical systems across the entire production span.
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