Suzuki VS1400 Intruder 1987-2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: VS1400 Intruder Model Nickname: Boulevard S83 (North America) Generation Generation Code: VX51 Codes Chassis Code: VX51 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Owners, DIY mechanics, professional technicians working on the VS1400 Intruder Competitive Analysis Competitors: Honda Shadow, Yamaha Virago, Kawasaki Vulcan Key Features Features: V-twin engine, shaft drive, classic cruiser styling, extensive production run Value Proposition Purpose: To provide comprehensive, accurate, and accessible repair and maintenance information for the Suzuki VS1400 Intruder, enabling owners to maintain their motorcycles effectively. 📋 Manual Details Coverage Areas Covered Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Page Count Total Pages: 426 Manual Type Type: Workshop Service Repair Manual Content Source: Likely based on official Suzuki factory service manuals. Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, starting, charging systems Transmission: Transmission inspection, disassembly, assembly, and adjustment Drivetrain: Driveshaft, rear wheel drive, final drive Suspension: Front fork, rear shock absorber, swingarm, and related components Brakes: Front and rear brake systems, hydraulic components, pad replacement Electrical: Wiring diagrams, lighting, ignition, battery, charging system, electronic controls Fuel System: Carburetor(s) (Mikuni BSR series), fuel lines, fuel tank, fuel pump (if applicable) Exhaust System: Exhaust pipes, mufflers, gaskets Wheels And Tires: Wheel bearing inspection, tire pressure, tire replacement Frame And Bodywork: Frame components, body panels, seat, fuel tank mounting Ignition System: Ignition timing, spark plug specifications, CDI unit troubleshooting. Starting Charging: Starter motor, starter clutch, battery, generator/alternator testing and replacement. Clutch: Clutch operation, adjustment, plate replacement, spring specifications. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, brake fluid changes, coolant checks Troubleshooting: Diagnostic procedures for common issues, electrical troubleshooting charts Repair: Detailed step-by-step repair instructions for all major components Disassembly Assembly: Comprehensive procedures for taking apart and reassembling components Adjustment: Carburetor synchronization, clutch adjustment, brake lever adjustment, cable adjustments Technical Specifications: Torque specifications, wear limits, fluid capacities, electrical values Electrical Diagnostics: Includes wiring diagrams, troubleshooting flowcharts for common electrical faults, testing of charging system components, ignition system components. Torque Specifications: Extensive torque specifications for all critical fasteners throughout the motorcycle. Technical Depth Depth: Comprehensive from basic maintenance to in-depth engine rebuilding and electrical diagnostics. Visual Aids: Detailed illustrations, exploded diagrams, drawings, and photographs Special Tools: Identification and usage instructions for required special service tools Documentation Style: Clear, concise explanations with emphasis on safety precautions and correct procedures, supported by visual aids. 📊 Manual Specifications File Format Quality: High-resolution PDF, suitable for printing Searchability: Likely searchable text within the PDF for quick information retrieval Print Quality Printable: Yes, all pages are printable Binding Type Type: Digital (PDF) Paper Type Type: N/A (Digital Format) Compatibility Operating Systems: Windows, Mac, Linux Required Software: Adobe Reader or compatible PDF viewer ⚙️ Engine Specifications Primary Engine Type: Four-stroke, V-twin, SOHC, 2 valves per cylinder Displacement: 1360cc (83 cubic inches) Bore X Stroke: 82.0 mm x 81.0 mm (approx.) Compression Ratio: 9.3:1 (typical) Cooling System: Air-cooled Performance Horsepower: Approx. 60-65 HP (varies by year and market) Torque: Approx. 70-75 lb-ft (varies by year and market) Fuel System Carburetion: Twin Mikuni BSR36 carburetors Fuel Type: Unleaded gasoline Lubrication Oil Capacity: Approx. 4.5 liters (4.8 US quarts) with filter change Recommended Oil: Refer to manual for specific viscosity (e.g., 10W-40, 20W-50, API SG or higher) 🔧 Transmission Standard Type: 5-speed constant mesh Features Drive Type: Shaft drive Clutch Type: Wet multi-plate 📐 Dimensions Exterior Length: Approx. 2345 mm (92.3 in) Width: Approx. 880 mm (34.6 in) Height: Approx. 1170 mm (46.1 in) Wheelbase: Approx. 1605 mm (63.2 in) Weights Dry Weight: Approx. 224 kg (494 lbs) Gross Vehicle Weight Rating: Refer to manual Fuel Tank Capacity: Approx. 12.0 liters (3.2 US gal) 🛡️ Safety Features Ratings Safety Standards: Meets relevant national and international motorcycle safety standards. Active Features Braking System: Disc front brake, Drum rear brake (earlier models may have drum front), ABS not typically standard on this model. Passive Features Lighting: Headlight, taillight, brake light, turn signals Structural: Steel frame construction 💡 Technology Features Infotainment System: Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems. Driver Assistance Features: None typically offered, as it predates widespread motorcycle driver assistance technologies. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. Air Filter: Inspect every 5,000 km (3,000 miles), clean or replace as needed. Replacement interval typically 10,000-15,000 km (6,000-9,000 miles). Spark Plugs: Replace every 10,000-12,000 km (6,000-7,500 miles) or as specified in the manual. Valve Clearance: Inspect and adjust every 10,000-15,000 km (6,000-9,000 miles). Fluid Specifications Brake Fluid: DOT 3 or DOT 4 (check manual for specific recommendation) Fork Oil: Refer to manual for specific viscosity and...
Owners, DIY mechanics, professional technicians working on the VS1400 Intruder
Competitive Analysis
Competitors:
Honda Shadow, Yamaha Virago, Kawasaki Vulcan
Key Features
Features:
V-twin engine, shaft drive, classic cruiser styling, extensive production run
Value Proposition
Purpose:
To provide comprehensive, accurate, and accessible repair and maintenance information for the Suzuki VS1400 Intruder, enabling owners to maintain their motorcycles effectively.
Includes wiring diagrams, troubleshooting flowcharts for common electrical faults, testing of charging system components, ignition system components.
Torque Specifications:
Extensive torque specifications for all critical fasteners throughout the motorcycle.
Technical Depth
Depth:
Comprehensive from basic maintenance to in-depth engine rebuilding and electrical diagnostics.
Visual Aids:
Detailed illustrations, exploded diagrams, drawings, and photographs
Special Tools:
Identification and usage instructions for required special service tools
Documentation Style:
Clear, concise explanations with emphasis on safety precautions and correct procedures, supported by visual aids.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, suitable for printing
Searchability:
Likely searchable text within the PDF for quick information retrieval
Print Quality
Printable:
Yes, all pages are printable
Binding Type
Type:
Digital (PDF)
Paper Type
Type:
N/A (Digital Format)
Compatibility
Operating Systems:
Windows, Mac, Linux
Required Software:
Adobe Reader or compatible PDF viewer
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, V-twin, SOHC, 2 valves per cylinder
Displacement:
1360cc (83 cubic inches)
Bore X Stroke:
82.0 mm x 81.0 mm (approx.)
Compression Ratio:
9.3:1 (typical)
Cooling System:
Air-cooled
Performance
Horsepower:
Approx. 60-65 HP (varies by year and market)
Torque:
Approx. 70-75 lb-ft (varies by year and market)
Fuel System
Carburetion:
Twin Mikuni BSR36 carburetors
Fuel Type:
Unleaded gasoline
Lubrication
Oil Capacity:
Approx. 4.5 liters (4.8 US quarts) with filter change
Recommended Oil:
Refer to manual for specific viscosity (e.g., 10W-40, 20W-50, API SG or higher)
🔧 Transmission
Standard
Type:
5-speed constant mesh
Features
Drive Type:
Shaft drive
Clutch Type:
Wet multi-plate
📐 Dimensions
Exterior
Length:
Approx. 2345 mm (92.3 in)
Width:
Approx. 880 mm (34.6 in)
Height:
Approx. 1170 mm (46.1 in)
Wheelbase:
Approx. 1605 mm (63.2 in)
Weights
Dry Weight:
Approx. 224 kg (494 lbs)
Gross Vehicle Weight Rating:
Refer to manual
Fuel Tank Capacity:
Approx. 12.0 liters (3.2 US gal)
🛡️ Safety Features
Ratings
Safety Standards:
Meets relevant national and international motorcycle safety standards.
Active Features
Braking System:
Disc front brake, Drum rear brake (earlier models may have drum front), ABS not typically standard on this model.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals
Structural:
Steel frame construction
💡 Technology Features
Infotainment
System:
Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems.
Driver Assistance
Features:
None typically offered, as it predates widespread motorcycle driver assistance technologies.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first.
Air Filter:
Inspect every 5,000 km (3,000 miles), clean or replace as needed. Replacement interval typically 10,000-15,000 km (6,000-9,000 miles).
Spark Plugs:
Replace every 10,000-12,000 km (6,000-7,500 miles) or as specified in the manual.
Valve Clearance:
Inspect and adjust every 10,000-15,000 km (6,000-9,000 miles).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific recommendation)
Fork Oil:
Refer to manual for specific viscosity and quantity (e.g., SAE 10W)
Final Drive Oil:
Refer to manual for specific viscosity (e.g., SAE 80W-90 GL-5)
Known Issues
Common Problems:
Carburetor jetting and synchronization can be sensitive, occasional charging system issues (stator/regulator), wear on steering head bearings, drive shaft splines may require lubrication.
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki, a Japanese manufacturer, has a long history of producing motorcycles known for their performance and reliability across various segments.
Model Evolution
Introduction Year:
1987
Key Updates Through 2004:
Minor styling updates, potential carburetor or ignition refinements. The core design remained consistent, leading to the North American 'Boulevard S83' designation for later models.
Production
Production Period:
1987-2004 (with continuation as Boulevard S83)
Manufacturing Location:
Japan (primary)
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards are not typically listed for individual model years of this era, the VS1400 Intruder was recognized for its strong V-twin engine, comfortable ride, and classic cruiser styling, making it a popular choice in its segment.
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