1987 Suzuki Intruder 700 Free Repair Manual

The 1987 Suzuki Intruder 700 is a classic V-twin cruiser motorcycle featuring a 699cc four-stroke engine, shaft drive system, hydraulic disc brakes, and distinctive cruiser styling. This comprehensive repair manual covers maintenance procedures, troubleshooting, specifications, and step-by-step repair instructions for DIY mechanics and professional technicians.

1. General Information 2. Maintenance Schedule 3. Engine Repair 4. Transmission & Drive System 5. Fuel System 6. Electrical System 7. Brake System 8. Suspension & Steering 9. Specifications 10. Troubleshooting

General Information

This manual provides detailed instructions for proper maintenance and repair of the 1987 Suzuki Intruder 700. Always follow safety precautions and use proper tools.

Section	Description
Identification	VIN location, model codes, production dates
Safety First	Important safety warnings and precautions
Tools Required	Recommended tools for maintenance and repair
Break-in Procedure	Proper engine break-in recommendations
Lubrication Points	All lubrication locations and intervals

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Pre-ride inspection: Check tires, brakes, lights, fluid levels
Every 600 miles: Oil change, chain adjustment, brake inspection
Every 3,000 miles: Air filter cleaning, spark plug replacement
Every 6,000 miles: Carburetor synchronization, valve adjustment
Annual: Brake fluid flush, coolant replacement

WARNING! Always use genuine Suzuki parts for optimal performance and safety.

Engine Repair

The 699cc V-twin engine requires proper procedures for disassembly and reassembly.

Cylinder Head: Valve adjustment specs: 0.004-0.006 in (0.10-0.15 mm)
Piston & Rings: Standard bore: 76.0 mm, maximum oversize: 76.5 mm
Crankshaft: Main bearing clearance: 0.0008-0.0020 in (0.020-0.051 mm)
Camshaft: Chain tension adjustment procedure
Oil System: Capacity: 3.2 qt (3.0 L) with filter change

Transmission & Drive System

5-speed constant mesh transmission with shaft final drive.

Transmission: Gear ratios: 1st-2.833, 2nd-1.875, 3rd-1.368, 4th-1.095, 5th-0.913

Clutch: Wet multi-plate type, adjustment at lever and cable

Drive Shaft: Universal joint inspection and lubrication points

Final Drive: Gear oil capacity: 5.3 oz (160 ml), SAE 80-90 gear oil

Fuel System

Mikuni BST34SS carburetors with vacuum-operated petcock.

Carburetor disassembly: Remove float bowl, jets, needles
Cleaning: Use carburetor cleaner and compressed air
Adjustment: Pilot screw 1-1/2 turns out, float height 21.5 mm
Synchronization: Use vacuum gauges for balanced operation
Fuel pump: Test pressure and flow rate

Tip: Always drain fuel before storage to prevent carburetor issues.

Electrical System

12-volt DC system with electronic ignition.

Component	Specification
Battery	12V 14Ah, maintenance type
Alternator	Three-phase AC generator, 280W output
Starter Motor	DC motor, 0.8 kW output
Spark Plugs	NGK D8EA, gap 0.024-0.028 in (0.6-0.7 mm)
Ignition Timing	Electronic, non-adjustable

Brake System

Hydraulic disc brakes front and rear with single-piston calipers.

Front Brake: Dual disc, 275 mm diameter
Rear Brake: Single disc, 275 mm diameter
Brake Fluid: DOT 4, replace every 2 years
Pad Wear: Replace when thickness below 1 mm
Bleeding: Procedure for removing air from system

Suspension & Steering

Telescopic front forks and dual shock rear suspension.

Front Fork: Oil capacity 486 ml per leg, SAE 10W
Rear Shocks: Spring preload adjustment, 5 positions
Steering Head: Bearing adjustment and lubrication
Wheel Bearings: Inspection and replacement procedure
Tire Pressure: Front 28 psi, rear 32 psi (cold)

WARNING! Always support motorcycle properly when working on suspension components.

Specifications

Engine: 699cc, 4-stroke, V-twin, SOHC, air-cooled
Bore x Stroke: 76.0 x 77.0 mm
Compression Ratio: 9.5:1
Power Output: 55 hp @ 7,500 rpm
Torque: 44 lb-ft @ 6,000 rpm
Fuel Capacity: 3.7 gal (14 L)
Weight: 476 lb (216 kg) wet
Seat Height: 27.6 in (700 mm)
Wheelbase: 62.4 in (1,585 mm)

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Weak battery, dirty carburetor	Charge battery, clean carburetor jets
Poor idle	Vacuum leak, sync issue	Check hoses, synchronize carburetors
Oil consumption	Worn rings, valve seals	Compression test, inspect valve seals
Brake fade	Contaminated fluid, worn pads	Flush brake fluid, replace pads
Electrical issues	Bad connections, regulator	Check grounds, test charging system

Note: Always diagnose systematically from simplest to most complex causes.

Technical Support: Consult authorized Suzuki dealer for complex issues