1987-2004 Suzuki VS1400 OEM Service Manual 99500-39156-03E

The Suzuki VS1400 OEM Service Manual (Part No. 99500-39156-03E) provides comprehensive technical information for the Suzuki VS1400 Intruder motorcycle manufactured between 1987 and 2004. This official factory manual covers complete maintenance procedures, repair instructions, specifications, and troubleshooting guides for the 1360cc V-twin engine, chassis, electrical systems, and all components. Below are key sections for safety, maintenance procedures, specifications, troubleshooting, and technical data.

1. General Information 2. Maintenance Schedule 3. Lubrication System 4. Fuel System 5. Cooling System 6. Engine Top End 7. Engine Bottom End 8. Clutch & Transmission 9. Electrical System 10. Chassis & Suspension 11. Troubleshooting

General Information

This manual covers all VS1400 Intruder models from 1987 through 2004. Includes model identification, vehicle identification numbers, general specifications, and safety precautions.

Item	Specification
Model Years	1987-2004
Engine Type	4-stroke, 45° V-twin, SOHC
Displacement	1360cc (83 cu in)
Bore x Stroke	94.0 x 98.0 mm
Compression Ratio	9.2:1
Fuel System	Mikuni BDS34 carburetors
Ignition System	Transistorized electronic
Starter System	Electric
Transmission	5-speed constant mesh
Final Drive	Shaft drive

Maintenance Schedule

Regular maintenance intervals and procedures to ensure optimal performance and longevity.

Pre-ride inspection: Check tires, brakes, lights, fluids before each ride.
Initial 600 mile service: Oil change, valve clearance check, carb sync.
Every 3,500 miles: Engine oil and filter replacement.
Every 7,500 miles: Air filter cleaning/replacement, spark plug replacement.
Every 15,000 miles: Valve clearance adjustment, throttle cable lubrication.

WARNING! Always use genuine Suzuki parts and recommended lubricants. Follow torque specifications precisely.

Lubrication System

Complete oil system service procedures and specifications.

Oil capacity: 3.7 liters (3.9 US qt) with filter change.
Oil type: API SE, SF, or SG grade, SAE 10W-40.
Oil pressure: 50 kPa (7.3 psi) at idle, 350-550 kPa (51-80 psi) at 3,000 rpm.
Oil pump: Trochoid type, driven by crankshaft.
Oil filter: Replace with every oil change using genuine Suzuki filter.

CAUTION! Never run engine with low oil level. Check oil when engine is warm and level.

Fuel System

Carburetors: Mikuni BDS34 constant velocity, 34mm bore.
Fuel Capacity: 13.5 liters (3.6 US gal) including 3.0 liter reserve.
Main Jet: #115 (front), #112.5 (rear) - standard setting.
Pilot Jet: #40 (front and rear) - standard setting.
Float Height: 21.5 ± 1.0 mm.
Idle Speed: 950 ± 50 rpm.
Fuel Pump: Electric, 1.8-2.2 psi pressure.

Cooling System

Liquid cooling system maintenance and service procedures.

Components: Radiator, water pump, thermostat, cooling fan, hoses.

Coolant capacity: 2.3 liters (2.4 US qt). Coolant type: Ethylene glycol antifreeze mixed 1:1 with distilled water. Thermostat: Opens at 80-84°C (176-183°F). Radiator cap pressure: 108-137 kPa (15.7-19.9 psi). Water pump: Mechanical, driven by timing gears.

Engine Top End

Cylinder head, valves, camshaft service procedures.

Remove fuel tank and air cleaner assembly.
Remove valve cover and camshaft cover.
Check valve clearance: Intake 0.10-0.15 mm, Exhaust 0.15-0.20 mm.
Camshaft runout limit: 0.05 mm maximum.
Valve stem-to-guide clearance: 0.025-0.052 mm (intake), 0.040-0.067 mm (exhaust).

Tip: Always replace valve cover gaskets during disassembly.

Engine Bottom End

Crankshaft, connecting rods, pistons, and cylinder service.

Piston clearance: 0.030-0.045 mm.
Piston ring end gap: 0.2-0.4 mm (top), 0.2-0.4 mm (second), 0.25-0.45 mm (oil).
Connecting rod big end clearance: 0.020-0.052 mm.
Crankshaft runout: 0.03 mm maximum.
Cylinder bore: 94.000-94.015 mm standard.
Piston diameter: 93.965-93.980 mm standard.

WARNING! Engine must be completely clean before disassembly. Mark all components for proper reassembly.

Clutch & Transmission

Wet multi-plate clutch and 5-speed transmission service.

Component	Specification
Clutch Type	Wet multi-plate
Number of Plates	9 friction, 8 metal
Clutch Spring Free Length	48.0 mm (service limit 46.5 mm)
Transmission Type	5-speed constant mesh
Gear Ratios	1st: 2.666, 2nd: 1.785, 3rd: 1.333, 4th: 1.095, 5th: 0.916
Final Drive Ratio	3.067 (37/12)

Electrical System

Complete electrical system specifications and troubleshooting.

Battery: 12V 14Ah, maintenance-free type.
Charging System: Three-phase AC generator, 28A at 5,000 rpm.
Starter Motor: 0.9 kW reduction type.
Spark Plugs: NGK DPR8EA-9 or ND X24EPR-U9, gap 0.8-0.9 mm.
Ignition Timing: 10° BTDC at 1,200 rpm, 35° BTDC at 3,500 rpm.
Headlight: 60/55W halogen, H4 type.

Chassis & Suspension

Frame, suspension, brakes, and wheels service procedures.

Front Suspension: Telescopic fork, 140 mm travel. Fork oil capacity: 435 ml per leg, SAE 10W. Rear Suspension: Dual shocks, 5-way preload adjustment, 90 mm travel. Front Brake: Dual disc, 290 mm diameter. Rear Brake: Single disc, 275 mm diameter. Tires: Front 110/90-19, Rear 170/80-15. Wheel Alignment: Toe-in 0-5 mm.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plugs, battery voltage, compression.
Poor idle	Carb sync, vacuum leaks	Synchronize carburetors, check for vacuum leaks, adjust idle mixture.
Overheating	Coolant, thermostat	Check coolant level, radiator cap, thermostat operation, water pump.
Electrical issues	Battery, charging system	Test battery voltage, regulator/rectifier output, stator resistance.
Transmission noise	Oil level, worn gears	Check oil level and condition, inspect transmission gears and bearings.

Technical Support: Contact authorized Suzuki dealer for complex repairs.

Parts Information: Use genuine Suzuki parts for optimal performance and reliability.