1988 Suzuki Intruder 750 Service Manual

The 1988 Suzuki Intruder 750 is a V-twin cruiser motorcycle featuring a 749cc four-stroke engine, shaft drive system, hydraulic disc brakes, and distinctive cruiser styling. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper upkeep and servicing of your motorcycle. Below are key sections for safety, maintenance schedules, technical specifications, engine service, electrical systems, and troubleshooting.

1. Features and Specifications 2. Safety Precautions 3. Maintenance Schedule 4. Engine Service 5. Fuel System 6. Electrical System 7. Chassis and Suspension 8. Brake System 9. Troubleshooting 10. Torque Specifications

Features and Specifications

Key components: 749cc V-twin engine, shaft final drive, hydraulic disc brakes, cruiser styling with stepped seat and pullback handlebars.

Feature	Description
Engine Type	4-stroke, V-twin, SOHC, air-cooled
Displacement	749cc
Bore x Stroke	76.0 x 82.5 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, single piston
Fuel Capacity	3.7 gallons (14 liters)

Safety Precautions

Always follow safety procedures when servicing your motorcycle.

Work in well-ventilated area: Avoid inhaling exhaust fumes or chemical vapors.
Use proper tools: Ensure all tools are in good condition and appropriate for the task.
Disconnect battery: Always disconnect negative terminal first when working on electrical system.
Support motorcycle securely: Use center stand or proper motorcycle lift.

WARNING! Gasoline is highly flammable; keep away from sparks, flames, and heat sources. Always work in well-ventilated area.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Every 600 miles/1000 km: Check engine oil level, tire pressure, chain tension, brake operation.
Every 3,000 miles/5,000 km: Change engine oil and filter, inspect spark plugs, check valve clearance.
Every 6,000 miles/10,000 km: Clean air filter, check carburetor synchronization, inspect brake pads.
Every 12,000 miles/20,000 km: Change final drive oil, inspect wheel bearings, check steering head bearings.

CAUTION! Always use genuine Suzuki parts and recommended lubricants for optimal performance.

Engine Service

Oil Change: Use SAE 10W-40 motorcycle oil, capacity 2.7 quarts with filter change.
Valve Clearance: Intake: 0.03-0.07 mm, Exhaust: 0.08-0.12 mm (cold)
Spark Plugs: NGK D8EA, gap 0.7-0.8 mm
Compression: Standard: 142 psi, Minimum: 114 psi
Cooling System: Air-cooled with oil cooler
Ignition Timing: Electronic advance, non-adjustable
Idle Speed: 1,100 ± 100 rpm

Fuel System

Mikuni BS34SS constant velocity carburetors with choke system.

Carburetor Settings: Main jet #115, Pilot jet #42.5, Needle jet 4DP42, Float height 23.0 ± 1.0 mm.

Synchronization: Use vacuum gauges to balance carburetors at 1,500 rpm. Fuel filter: Replace every 12,000 miles. Fuel lines: Inspect for cracks and replace if necessary.

Electrical System

12V DC system with electronic CDI ignition and maintenance-free battery.

Battery: YT12A-BS, 12V 10Ah, keep terminals clean and tight.
Charging System: Three-phase AC generator, output 280W at 5,000 rpm.
Starter: DC electric starter with reduction gear.
Fuses: Main fuse 30A, sub fuses 10A and 15A.

Tip: Always disconnect battery before performing electrical work to prevent short circuits.

Chassis and Suspension

Double cradle steel frame with telescopic front fork and dual shock rear suspension.

Front Suspension: Telescopic fork, oil capacity 435cc per leg, spring preload adjustable.
Rear Suspension: Dual shock absorbers, 5-position spring preload adjustment.
Steering Head Bearings: Tapered roller bearings, check for play every 6,000 miles.
Wheels: Cast aluminum, front 19-inch, rear 15-inch.
Tires: Front 100/90-19, Rear 140/90-15, pressure 28 psi front, 32 psi rear.

WARNING! Always check tire pressure and condition before riding. Replace tires if tread depth is below 1/32 inch.

Brake System

Hydraulic disc brakes front and rear with single piston calipers.

Front Brake: Disc diameter 275mm, pad thickness minimum 1.5mm. Rear Brake: Disc diameter 275mm, pad thickness minimum 1.5mm. Brake Fluid: DOT 4, replace every 2 years. Brake Lines: Inspect for cracks and wear regularly.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Weak battery, fuel issue, spark	Check battery voltage, fuel flow, spark plug condition
Poor idle	Dirty carburetor, vacuum leak	Clean carburetor, check intake manifold seals
Overheating	Low oil, rich mixture	Check oil level, inspect carburetor settings
Electrical failure	Blown fuse, bad connection	Check fuses, inspect wiring connections
Brake drag	Stuck caliper, contaminated fluid	Clean caliper pistons, replace brake fluid

Reset: Disconnect battery for 30 minutes to reset ECU if applicable.

Service: Contact authorized Suzuki dealer for complex repairs and warranty service.