1986 Suzuki Intruder 750 Manual

The 1986 Suzuki Intruder 750 is a classic V-twin cruiser motorcycle featuring a 749cc four-stroke engine, shaft drive system, hydraulic disc brakes, electronic ignition, and distinctive cruiser styling. This manual covers essential information for maintenance, operation, specifications, and troubleshooting of this iconic motorcycle. Below are key sections for safety, features, maintenance procedures, specifications, and technical details.

1. Features at a Glance 2. Safety Information 3. Maintenance Schedule 4. Specifications 5. Controls and Instruments 6. Engine Maintenance 7. Electrical System 8. Brake System 9. Troubleshooting 10. Storage Guidelines

Features at a Glance

Key components: 749cc V-twin engine, shaft final drive, hydraulic disc brakes, electronic ignition, cruiser styling with low seat height.

Feature	Description
Engine Type	4-stroke, V-twin, air-cooled
Displacement	749cc
Bore x Stroke	78.0 x 78.4 mm
Compression Ratio	9.5:1
Fuel System	Mikuni BS34SS carburetors
Ignition System	Electronic CDI
Final Drive	Shaft drive
Front Brake	Hydraulic disc, single piston
Rear Brake	Hydraulic disc
Seat Height	700 mm (27.6 inches)

Safety Information

Always wear proper protective gear and inspect motorcycle before riding.

Pre-ride inspection: Check tires, brakes, lights, and fluid levels.
Protective gear: Always wear helmet, eye protection, gloves, and protective clothing.
Riding position: Maintain proper riding posture for control and comfort.
Load limits: Do not exceed maximum weight capacity of 397 lbs (180 kg).

WARNING! Motorcycle operation requires skill and attention. Never operate under influence of alcohol or drugs.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily checks: Tire pressure, brake operation, fluid leaks.
Every 600 miles: Oil change, chain adjustment, brake inspection.
Every 3,000 miles: Spark plugs, air filter, carburetor sync.
Every 6,000 miles: Valve clearance check, brake fluid change.
Annual: Comprehensive inspection of all systems.

CAUTION! Use only Suzuki genuine parts for replacement to maintain performance and safety.

Specifications

Overall Length: 2,290 mm (90.2 inches)
Overall Width: 830 mm (32.7 inches)
Overall Height: 1,110 mm (43.7 inches)
Wheelbase: 1,610 mm (63.4 inches)
Ground Clearance: 140 mm (5.5 inches)
Dry Weight: 223 kg (492 lbs)
Fuel Capacity: 12 liters (3.2 US gallons)
Oil Capacity: 2.7 liters (2.9 US quarts)
Transmission: 5-speed constant mesh
Front Tire: 110/90-16
Rear Tire: 140/90-15

Controls and Instruments

Familiarize yourself with all controls before riding.

Handlebar Controls: Right side - engine stop switch, start button, front brake lever. Left side - clutch lever, turn signals, horn, headlight dimmer.

Instrument Panel: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators, oil pressure warning light.

Foot Controls: Right side - rear brake pedal, gear shift lever. Left side - sidestand.

Engine Maintenance

Proper engine care ensures reliable performance.

Oil change: Every 600 miles or 6 months using 10W-40 motorcycle oil.
Air filter: Clean every 3,000 miles, replace if damaged.
Spark plugs: NGK D8EA, gap 0.7-0.8 mm, replace every 3,000 miles.
Valve clearance: Check every 6,000 miles - intake 0.03-0.07 mm, exhaust 0.08-0.12 mm.
Carburetor sync: Perform every 3,000 miles for smooth operation.

Tip: Always warm up engine before riding and allow to cool before servicing.

Electrical System

12-volt DC system with electronic ignition.

Battery: 12V 14Ah, maintain proper electrolyte level.
Charging system: Three-phase AC generator, regulated output.
Fuses: Main fuse 30A, accessory fuses 10A and 15A.
Lights: Headlight 60/55W, tail/brake light 8/27W, turn signals 21W.

WARNING! Disconnect battery before electrical work to prevent shorts.

Brake System

Hydraulic disc brakes front and rear.

Front brake: Single disc, single piston caliper.
Rear brake: Single disc, single piston caliper.
Brake fluid: DOT 4, change every 2 years or 12,000 miles.
Brake pads: Replace when worn to 1 mm thickness.
Bleeding: Required when fluid appears discolored or after component replacement.

CAUTION! Test brakes after service before riding. Never reuse brake fluid.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel supply, spark plugs, battery charge, carburetor
Poor idle	Carburetor sync, air filter	Sync carburetors, clean air filter, adjust idle mixture
Brakes feel soft	Air in system, worn pads	Bleed brake system, inspect/replace brake pads
Electrical failure	Battery, fuses, connections	Check battery voltage, inspect fuses, clean connections
Transmission issues	Clutch adjustment, oil level	Adjust clutch cable, check transmission oil level

Service: Consult authorized Suzuki dealer for complex repairs.

Storage Guidelines

Proper storage prevents damage during extended non-use.

Fuel system: Add fuel stabilizer and run engine for 5 minutes.
Battery: Remove and store fully charged in cool, dry place.
Tires: Inflate to maximum pressure and store off ground.
Exterior: Clean thoroughly and apply protective coating.
Cover: Use breathable motorcycle cover in dry storage area.

CAUTION! Do not store with fuel in carburetors to prevent varnish buildup.