Suzuki VS700GL, VS750GL, VS800GL Intruder & Boulevard S50 1986-2009 - Comprehensive Motorcycle Service & Repair Manual

Suzuki VS700, VS750 & VS800 Intruder / Boulevard S50 (1986-2009) - Service & Repair Manual

Master your machine with the ultimate technical authority for the Suzuki VS series. This comprehensive service manual is the definitive resource for maintaining, troubleshooting, and overhauling one of Suzuki's most iconic V-twin cruiser lineups. From the early VS700 models to the final Boulevard S50 production years, this guide provides the precision data required for professional-grade results.

Engineered for Performance

The Suzuki VS series represents a masterpiece of motorcycle engineering, featuring a liquid-cooled, 45-degree V-twin engine and a reliable shaft drive mechanism. To keep these sophisticated systems—including the Twin Swirl Combustion System (TSCC) and fully transistorized ignition—running at peak performance, specific technical knowledge is essential. This manual serves as your expert companion for every nut and bolt.

Unmatched Model Coverage

This manual includes specialized supplement chapters covering the evolution of the series across more than two decades:

• Intruder 700 Series: VS700GLF, VS700GLP (1986), VS700GLE, VS700GLH (1987)
• Intruder 750 Series: VS750GLJ (1988), VS750GLK (1989), VS750GLFL/PL (1990), VS750GLFM/PM (1991)
• Intruder 800 Series: VS800GLN (1992) through VS800GLK4 (2004)
• Boulevard S50 Series: VS800K5 (2005) through the final VS800K9 (2009) models

Professional Technical Highlights

• Serial Number Locations: Precise identification for registration and parts ordering. The Frame Serial Number (V.I.N.) is stamped on the steering head pipe, while the Engine Serial Number is located on the right rear of the crankcase.
• Engine Mastery: Detailed service for the 4-stroke V-twin, including cylinder identification (No. 1 rear, No. 2 front), compression testing (Standard 185-227 psi), and valve clearance adjustments (0.08–0.13 mm).
• Shaft Drive & Transmission: Complete teardown and reassembly of the 5-speed constant mesh transmission and the secondary bevel gear mechanism.
• Cooling & Electrical: Full schematics for the liquid cooling system (1.7L capacity) and the 12V electrical system, including wiring diagrams for all model variations.
• Periodic Maintenance: Comprehensive charts with intervals for battery service, spark plug heat range selection (NGK DP8EA-9 standard), and final gear oil changes (SAE 90 hypoid GL-5).

Why This Manual is Essential

Whether you are performing a simple oil change (2.4L capacity) or a complete engine overhaul (3.3L capacity), this manual provides the exact torque values—such as the 140-160 N-m required for the generator rotor bolt—and specialized materials needed for a perfect job. It includes critical safety precautions, breaking-in procedures for new components, and detailed troubleshooting guides to diagnose issues before they become costly repairs.

Specifications at a Glance

• Engine Type: 4-stroke, water-cooled, OHC, 45-degree V-twin
• Drive System: Maintenance-heavy shaft drive
• Fuel System: Mikuni BDS and BS series carburetors (specific tuning data included)
• Chassis: Telescopic front suspension and 5-way adjustable rear swinging arm
• Braking: Hydraulic front disc and internal expanding rear drum systems