1986 Suzuki Intruder Manual Download

The 1986 Suzuki Intruder is a classic cruiser motorcycle featuring V-twin engine configuration, shaft drive system, and distinctive styling. This comprehensive manual covers maintenance procedures, technical specifications, troubleshooting guides, and repair instructions for the 1986 model year. Below are key sections for specifications, maintenance schedules, operation, troubleshooting, and download options.

1. Specifications 2. Maintenance Schedule 3. Operation Instructions 4. Technical Data 5. Troubleshooting Guide 6. Repair Procedures 7. Electrical System 8. Fuel System 9. Brake System 10. Download Options

Specifications

Key technical specifications for the 1986 Suzuki Intruder motorcycle.

Feature	Description
Engine Type	4-stroke, V-twin, SOHC
Displacement	805cc
Bore x Stroke	78.0 x 84.0 mm
Compression Ratio	9.5:1
Fuel System	Mikuni BS34SS carburetors
Ignition System	Transistorized electronic
Transmission	5-speed constant mesh
Final Drive	Shaft drive
Front Suspension	Telescopic fork
Rear Suspension	Dual shocks, adjustable preload

Maintenance Schedule

Regular maintenance intervals and procedures for optimal performance.

Oil Change: Every 3,000 miles or 6 months
Oil Filter: Replace with every oil change
Air Filter: Clean every 6,000 miles, replace every 12,000 miles
Spark Plugs: Replace every 7,500 miles
Brake Fluid: Replace every 2 years
Coolant: Replace every 2 years or 24,000 miles
Drive Shaft: Lubricate every 7,500 miles

WARNING! Always use genuine Suzuki parts for replacement. Follow torque specifications precisely.

Operation Instructions

Proper starting, riding, and shutdown procedures.

Pre-ride inspection: Check tires, brakes, lights, and fluid levels
Starting procedure: Turn fuel valve to ON, set choke, turn ignition key
Warm-up: Allow engine to reach operating temperature before riding
Shifting: Use clutch smoothly, shift at recommended RPM ranges
Braking: Apply both front and rear brakes simultaneously
Storage: Use fuel stabilizer for long-term storage

CAUTION! Always wear proper protective gear. Never operate under influence of alcohol or drugs.

Technical Data

Overall Length: 2,390 mm (94.1 in)
Overall Width: 890 mm (35.0 in)
Overall Height: 1,140 mm (44.9 in)
Wheelbase: 1,645 mm (64.8 in)
Seat Height: 700 mm (27.6 in)
Ground Clearance: 140 mm (5.5 in)
Dry Weight: 229 kg (505 lbs)
Fuel Capacity: 13.5 liters (3.6 US gal)
Oil Capacity: 2.8 liters (3.0 US qt)

Troubleshooting Guide

Common issues and their solutions for the 1986 Suzuki Intruder.

Symptom	Possible Cause	Corrective Action
Hard starting	Dirty carburetor, weak battery	Clean carburetor jets, charge/replace battery
Poor idle	Vacuum leaks, dirty air filter	Check vacuum lines, replace air filter
Electrical issues	Bad connections, faulty regulator	Check wiring harness, test charging system
Brake problems	Worn pads, air in lines	Replace brake pads, bleed brake system
Transmission noise	Low oil, worn gears	Check oil level, inspect transmission

Repair Procedures

Step-by-step repair instructions for common maintenance tasks.

Carburetor cleaning: Remove, disassemble, clean jets, reassemble
Brake pad replacement: Remove caliper, replace pads, reassemble
Chain adjustment: Loosen axle nut, adjust chain slack to specification
Valve adjustment: Remove valve cover, set clearances to 0.08-0.13 mm
Spark plug replacement: Remove old plugs, gap new plugs to 0.7-0.8 mm

Tip: Use factory service manual for detailed torque specifications.

Electrical System

Electrical components and wiring diagram information.

Battery: 12V 14Ah
Alternator: Three-phase AC generator
Headlight: 60/55W halogen
Fuses: Main 30A, Headlight 10A, Signal 10A
Ignition Coil: Primary resistance 2-4 ohms

WARNING! Disconnect battery before performing electrical work.

Fuel System

Carburetor specifications and fuel system maintenance.

Main jet: #127.5
Pilot jet: #42.5
Needle jet: O-8
Float level: 22.4 ± 1.0 mm
Idle speed: 1,100 ± 100 rpm

CAUTION! Gasoline is highly flammable. Work in well-ventilated area.

Brake System

Front and rear brake specifications and maintenance procedures.

Component	Specification
Front Brake Type	Hydraulic disc, single piston
Rear Brake Type	Hydraulic disc, single piston
Front Disc Diameter	293 mm
Rear Disc Diameter	275 mm
Brake Fluid	DOT 4
Pad Thickness (min)	1.0 mm

Download Options

Available formats and download instructions for the complete manual.

PDF Format: Complete manual with searchable text
File Size: Approximately 45 MB
Pages: 328 pages including diagrams
Language: English
Compatibility: Windows, Mac, iOS, Android

Note: Manual includes detailed wiring diagrams, exploded views, and part numbers.