Suzuki VS 800 1992–2008 Service Repair Manual – PDF Download

🛠️ Suzuki VS 800 1992–2008 Service Repair Manual – PDF Download

🧰 Comprehensive factory service manual for the 1992–2008 Suzuki VS 800 Intruder motorcycle. This guide covers in-depth maintenance, diagnostics, and repair procedures for the fuel-efficient V-twin cruiser. A must-have for owners, restorers, and technicians working on the long-running VS800 model.

📲 Instant PDF Download – Searchable, printable, and compatible with all digital devices.

🔍 Model Background

The Suzuki VS 800 Intruder (1992–2008) was a mid-sized cruiser motorcycle designed for riders seeking a blend of classic chopper styling, smooth V-twin power, and easy handling. As the larger sibling in Suzuki’s popular Intruder lineup, the VS 800 delivered strong low-end torque and laid-back comfort—making it a favorite for new and experienced cruiser riders alike.

Powered by an 805cc liquid-cooled 45° V-twin engine, the VS 800 featured shaft drive, 4 valves per cylinder, and dual carburetors. This setup offered reliable power delivery, low maintenance, and a signature V-twin rumble that appealed to fans of traditional cruiser sound and feel.

The bike’s design included pullback handlebars, a teardrop tank, and forward foot controls, providing a relaxed upright riding position. With a low seat height and relatively light curb weight for its class, the VS 800 was easy to maneuver at low speeds and comfortable for long-distance rides.

Produced from 1992 through 2008, the Suzuki VS 800 Intruder remains a beloved model for those who appreciate retro cruiser aesthetics, mechanical simplicity, and smooth V-twin performance in a manageable midsize package.

📆 Model Years Covered:

• Suzuki VS 800 – 1992
• Suzuki VS 800 – 1993
• Suzuki VS 800 – 1994
• Suzuki VS 800 – 1995
• Suzuki VS 800 – 1996
• Suzuki VS 800 – 1997
• Suzuki VS 800 – 1998
• Suzuki VS 800 – 1999
• Suzuki VS 800 – 2000
• Suzuki VS 800 – 2001
• Suzuki VS 800 – 2002
• Suzuki VS 800 – 2003
• Suzuki VS 800 – 2004
• Suzuki VS 800 – 2005
• Suzuki VS 800 – 2006
• Suzuki VS 800 – 2007
• Suzuki VS 800 – 2008

📘 Manual Details:

• Engine: 805cc, 4-stroke, V-twin, SOHC
• Fuel System: Dual carburetors (Mikuni BDS36)
• Ignition: Electronic, transistorized
• Cooling System: Air/oil-cooled with cooling fins and oil cooler
• Transmission: 5-speed manual
• Final Drive: Shaft
• Brakes:
  • Front: Hydraulic disc
  • Rear: Drum
• Suspension:
  • Front: Telescopic fork
  • Rear: Dual shock absorbers with preload adjustability
• Electrical System: 12V with complete wiring schematics
• Pages: 500+ (shared across VS series)
• Language: English

📚 Manual Sections Include:

• Intro & Specifications
• General service info, maintenance schedule, torque specs
• Engine Service
• Cylinder head, piston, valve clearance, cam chain, crankcase
• Fuel & Carburetor
• Cleaning, float adjustment, mixture screws, sync procedure
• Electrical System
• Wiring diagrams, starter, ignition coil, switches, charging system
• Transmission & Clutch
• Gear selector, clutch assembly, adjustment, shift drum
• Chassis & Suspension
• Front fork rebuild, shock absorber replacement, steering stem
• Braking System
• Disc inspection, drum adjustment, pad replacement, bleeding
• Final Drive
• Shaft lubrication, gear inspection, coupling service

💾 Format & Compatibility:

• File Format: PDF (Digital Download)
• Searchable: ✅ Yes
• Printable: ✅ Yes – Print the full manual or specific chapters
• Compatible With: Windows, macOS, Android, iOS, Linux

🔍 Keywords:

Suzuki VS800 service manual PDF, VS 800 Intruder repair guide, 805cc V-twin maintenance, carburetor tuning, shaft drive, wiring diagrams

❓ Mini FAQ:

Q: Is this manual specific to the VS 800 models?
A: Yes – it covers all VS800 models from 1992 to 2008 in complete detail.

Q: Does this include carburetor settings and specs?
A: Yes – full tuning and overhaul instructions for dual Mikuni BDS36 carbs are included.

🧭 Helpful Resources for Suzuki Motorcycle Owners

• Why Every Motorcycle Owner Should Own a Service Manual – Find out how a downloadable repair manual can simplify maintenance and help you troubleshoot common problems on your own.
• Motorcycle Troubleshooter – Not sure what’s wrong with your Suzuki motorcycle? Our free tool lists common issues and DIY fixes across all major motorcycle brands.

🔧 Browse More Suzuki Motorcycle Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your motorcycle shows serious issues, we strongly recommend visiting a certified mechanic. These guides are best suited for owners with basic to moderate mechanical experience.

Q: Can I use this on an iPad or mobile?
A: Absolutely – this PDF is compatible with all modern devices.