1986 Suzuki Intruder 700 Repair Manual Download

The 1986 Suzuki Intruder 700 is a classic V-twin cruiser motorcycle featuring a 699cc four-stroke engine, shaft drive system, and distinctive styling. This comprehensive repair manual covers all aspects of maintenance, troubleshooting, and repair for the 1986 model year. Below are key sections covering technical specifications, routine maintenance, engine repair, electrical systems, chassis, and troubleshooting procedures.

Technical Specifications

Complete technical data for the 1986 Suzuki Intruder 700 including engine specifications, dimensions, and performance characteristics.

Routine Maintenance

Regular maintenance schedule and procedures to keep your Intruder 700 in optimal condition.

1. Oil Change: Replace engine oil and filter every 3,000 miles or 6 months.
2. Spark Plugs: Inspect and replace every 7,500 miles.
3. Air Filter: Clean every 3,000 miles, replace every 12,000 miles.
4. Chain Adjustment: Check drive shaft fluid level every 6,000 miles.
5. Brake Fluid: Replace every 2 years or 12,000 miles.

WARNING! Always use genuine Suzuki parts and recommended lubricants. Work on level surface with proper tools.

Engine Repair

Comprehensive engine disassembly, inspection, and reassembly procedures.

1. Cylinder Head Removal: Remove exhaust, intake, and valve cover before head bolts.
2. Piston Removal: Remove cylinder after head removal; inspect rings and cylinder walls.
3. Valve Adjustment: Set intake clearance to 0.10-0.15mm, exhaust to 0.15-0.20mm.
4. Timing Chain: Check tensioner and guide wear during service.
5. Oil Pump: Inspect for wear and proper pressure (50-60 psi at 3000 rpm).

CAUTION! Engine components are precision parts; handle with care and use torque specifications.

Fuel System

• Carburetors: Mikuni BS34SS, synchronized adjustment required.
• Fuel Pump: Electric type, check pressure (2.5-3.0 psi).
• Fuel Filter: Replace every 12,000 miles or if contaminated.
• Idle Speed: Adjust to 1000 ± 100 rpm when warm.
• Float Level: Set to 22.5 ± 1.0mm from carburetor body.
• Pilot Screws: Factory setting 2 turns out from lightly seated.

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 14Ah, maintain specific gravity at 1.260-1.280. Charging System: Three-phase alternator, output 25A at 5000 rpm. Ignition: Electronic advance, check pickup coil resistance (90-120 ohms). Starter: DC motor, draw current less than 100A. Lights: Headlight 60/55W, brake light 21/5W.

Chassis & Suspension

Frame, suspension, and steering maintenance procedures.

1. Steering Head Bearings: Check for play every 6,000 miles.
2. Fork Oil: Replace every 12,000 miles with 10W fork oil.
3. Wheel Bearings: Inspect for smooth rotation and replace if rough.
4. Tire Pressure: Front 28 psi, rear 32 psi (cold).
5. Swingarm Pivot: Lubricate every 12,000 miles.

Tip: Always use a motorcycle stand for stability during chassis work.

Brake System

Front and rear brake system maintenance and repair.

1. Brake Pads: Replace when thickness reaches 1.0mm minimum.
2. Brake Discs: Check for warpage (max 0.3mm runout).
3. Brake Fluid: Use DOT 4 fluid; bleed system annually.
4. Master Cylinders: Rebuild if leaking or spongy feel.
5. Caliper Service: Clean and lubricate sliding pins every brake service.

WARNING! Brakes are critical safety components; test thoroughly after service.

Drive System

Shaft drive maintenance and universal joint service.

Drive Shaft: Inspect splines for wear during tire changes. Final Drive Oil: Replace every 12,000 miles with 80W-90 gear oil. Universal Joint: Check for play in drive system. Wheel Alignment: Ensure proper alignment to prevent drive train wear.

Troubleshooting

Reset: Clear trouble codes by disconnecting battery for 10 minutes.

Service: Contact authorized Suzuki dealer for complex repairs.