1986-2009 Suzuki VS700, VS750, VS800 Intruder & Boulevard S50 Service Manual (P/N 99500-38064-03e)

• Covers 1986–2009 Suzuki VS700, VS750, VS800 Intruder, and Boulevard S50 motorcycles.
• Details maintenance and service specifications specifically for the liquid-cooled V-twin drivetrain.
• Official Suzuki Motor Corporation publication (P/N 99500-38064-03e, copyright 1990).
• 539 pages of technical content, featuring exploded-view diagrams, torque tables, and detailed wiring schematics.

Mechanical and Chassis Documentation

This official Suzuki manual delivers a comprehensive technical breakdown of the V-twin engine, liquid cooling system, and shaft-drive mechanism. Content is logically organized into ten primary groups. You will find general information, periodic maintenance schedules, and complete parameters for engine and transmission teardowns. For mechanics handling deep engine work, the chapters extensively document cylinder head, camshaft, crankshaft, and piston tolerances. Transmission sections lay out shifting fork clearances alongside precise gear assembly data. Chassis documentation details everything from steering bearing checks to brake system purging and front fork oil specifications. Working on these older metric cruisers requires strict adherence to factory safety protocols, especially when handling pressurized fuel systems or heavy lifting, so always secure the bike properly before starting your diagnostic routines.

Specification Highlights

Having accurate data on hand eliminates guesswork on the shop floor. This reference material provides the precise technical data required for engine tuning and routine services. For instance, valve clearance for both intake and exhaust is strictly listed at 0.08–0.13 mm within the cylinder head specifications. You will also find the exact coolant system capacity (1.7 liters) and the final drive gear oil capacity (200–220 ml) needed for regular maintenance intervals. Detailed torque specifications are mapped out for all major fasteners. Expect to see values ranging from 9–11 Nm for the smaller cylinder head cover bolts, scaling up to 25 Nm for larger housing components. This manual is built to give both DIYers and professional technicians the exact factory metrics needed for an accurate, efficient workflow.