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