1987 Suzuki Intruder VS700 Factory Service Manual

The 1987 Suzuki Intruder VS700 Factory Service Manual provides comprehensive technical information for proper maintenance, repair, and service of the Suzuki VS700 Intruder motorcycle. This manual covers engine specifications, chassis components, electrical systems, troubleshooting procedures, and maintenance schedules. Below are key sections for specifications, maintenance procedures, troubleshooting, and technical data.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Fuel System 6. Chassis & Suspension 7. Electrical System 8. Troubleshooting 9. Wiring Diagrams 10. Torque Specifications 11. Special Tools

General Information

This factory service manual covers the 1987 Suzuki Intruder VS700 model. Includes identification numbers, safety precautions, and general service information.

Component	Location/Description
VIN Number	Stamped on steering head
Engine Number	Stamped on crankcase
Model Code	VS700GL
Manufacture Date	1986-1987
Service Intervals	Refer to maintenance schedule

Specifications

Engine Type: 4-stroke, V-twin, SOHC, air-cooled
Displacement: 699cc
Bore x Stroke: 80.0 x 69.6mm
Compression Ratio: 9.5:1
Fuel System: Mikuni BST33SS carburetors
Ignition System: Electronic CDI
Transmission: 5-speed constant mesh
Final Drive: Shaft drive
Front Suspension: Telescopic fork
Rear Suspension: Dual shocks, adjustable preload
Brakes: Front disc, rear drum
Fuel Capacity: 3.7 gallons (14 liters)
Dry Weight: 474 lbs (215 kg)

Periodic Maintenance

Regular maintenance schedule and procedures for optimal performance and longevity.

Oil Change: Every 3,000 miles - Use SAE 10W-40 motorcycle oil
Oil Filter: Replace with every oil change
Spark Plugs: Check/replace every 6,000 miles - NGK DR8ES-L
Air Filter: Clean every 3,000 miles, replace every 12,000 miles
Valve Clearance: Check every 6,000 miles - Intake: 0.03-0.07mm, Exhaust: 0.08-0.12mm
Drive Shaft Oil: Change every 12,000 miles
Brake Fluid: Replace every 2 years
Tire Pressure: Check weekly - Front: 28 psi, Rear: 36 psi

WARNING! Always use motorcycle-specific lubricants and follow torque specifications.

Engine Service

Complete engine disassembly, inspection, and reassembly procedures.

Service Procedure	Specification/Tool
Cylinder Head Removal	Follow sequence for bolt removal
Valve Service	Use valve spring compressor tool
Piston Installation	Arrow mark toward front
Cam Chain Tension	Automatic tensioner
Oil Pump	Check rotor clearance
Clutch	Fiber and steel plate replacement

Fuel System

Carburetor service, adjustment, and fuel delivery system maintenance.

Carburetor Sync: Use vacuum gauges for synchronization
Float Level: 21.5 ± 1.0mm
Pilot Screw: Factory setting: 2-1/4 turns out
Fuel Filter: Replace every 12,000 miles
Throttle Cables: Check for smooth operation and proper free play

CAUTION! Handle fuel with care in well-ventilated area away from ignition sources.

Chassis & Suspension

Frame, suspension, brakes, and wheel service procedures.

Front Fork Oil: SAE 10W, 435ml per leg
Steering Head Bearings: Adjust for smooth operation without play
Brake Pads: Replace when worn to 1mm thickness
Wheel Bearings: Check for smooth rotation and replace if rough
Chain/Sprockets: N/A - Shaft drive system
Tire Wear: Replace when tread depth below 1mm

Electrical System

Battery, charging system, ignition, and lighting circuit maintenance.

Component	Specification/Test
Battery	12V 14Ah, maintain specific gravity 1.280
Stator Output	14V AC at 5000 RPM
Regulator/Rectifier	Test diode function
Spark Plug Gap	0.7-0.8mm
Headlight	12V 60/55W H4
Fuses	Main: 30A, Headlight: 10A, Signal: 10A

Troubleshooting

Diagnostic procedures for common operating problems.

Symptom	Possible Cause	Corrective Action
Engine won't start	Weak battery, fouled plugs, fuel issue	Check battery voltage, spark, fuel delivery
Poor idle	Dirty carburetors, sync issue	Clean/sync carburetors, adjust mixture
Electrical failure	Blown fuse, bad connection	Check fuses, wiring connections
Overheating	Low oil, rich mixture	Check oil level, carburetor adjustment
Brake drag	Stuck caliper, cable issue	Clean/lubricate components

Wiring Diagrams

Complete electrical schematics for all circuits including charging, ignition, and lighting systems.

Note: Refer to fold-out diagrams in printed manual for full-size schematics. Color-coded wiring with connector locations and ground points.

Torque Specifications

Critical fastener torque values for safe and proper assembly.

Fastener	Torque (ft-lbs)	Torque (Nm)
Cylinder Head Bolts	30-33	41-45
Spark Plugs	11-17	15-23
Oil Drain Plug	18-22	25-30
Front Axle Nut	36-43	49-59
Rear Axle Nut	65-80	88-108
Wheel Nuts	25-30	34-41

Special Tools

Factory recommended tools for specific service procedures.

Carburetor Sync Tool: Suzuki tool no. 09912-64511
Valve Spring Compressor: Suzuki tool no. 09916-44511
Flywheel Puller: Suzuki tool no. 09930-30102
Clutch Holder: Suzuki tool no. 09920-53720
Steering Stem Wrench: Suzuki tool no. 09940-50121

Service Support: Contact authorized Suzuki dealer for technical assistance and genuine parts.