The 1999 Suzuki VS800GLX Intruder is a classic cruiser motorcycle renowned for its reliable 805cc V-twin engine, offering a smooth and consistent power delivery ideal for both city riding and longer journeys. Its timeless cruiser styling, characterized by comfortable ergonomics and a distinctive profile, positions it as a strong contender in its segment. Suzuki's reputation for engineering quality is evident in the VS800GLX's robust platform, which provides a dependable and engaging riding experience, making it a favored choice for riders who appreciate classic aesthetics and enduring performance. This comprehensive Service Repair Manual provides essential information for the maintenance and repair of the 1999 Suzuki VS800GLX Intruder. It covers all critical systems, including detailed procedures for the engine, transmission, fuel, ignition, electrical, braking, and suspension systems. The manual also includes valuable troubleshooting guides, diagnostic information, and technical specifications, empowering owners and technicians to effectively maintain, service, and repair the motorcycle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Suzuki Model: VS800GLX Intruder Year: 1999 Product Type: Service Repair Manual 👋 Introduction Market Position Category: Cruiser Motorcycle Target Audience: Owners and independent repair shops seeking comprehensive maintenance and repair data. Competitive Analysis Competitors: Honda Shadow series, Yamaha Virago series, Kawasaki Vulcan series of the same era. Key Features Engine Configuration: V-twin, air-cooled engine known for its reliable power delivery. Style: Classic cruiser styling with comfortable ergonomics for touring and city riding. Value Proposition: Offers a robust and dependable platform for customization and long-term ownership. 📋 Manual Details Coverage Areas General Coverage: Complete service and repair information for the 1999 Suzuki VS800GLX Intruder. Page Count Estimated Page Count: Approximately 300-400 pages (typical for this model and era's service manuals). Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, inspection, repair, and reassembly procedures for the 805cc V-twin engine. Transmission: Coverage of the 5-speed constant mesh transmission, clutch operation, and gearshift mechanism. Fuel System: Carburetor adjustment and overhaul, fuel pump operation, fuel line maintenance. Ignition System: Ignition timing, spark plug specifications, CDI unit diagnostics. Cooling System: Air cooling system principles and maintenance. Exhaust System: Exhaust pipe and muffler inspection and replacement. Brakes: Front and rear brake system inspection, caliper overhaul, pad replacement, fluid bleeding. Suspension: Front telescopic fork service, rear shock absorber inspection and adjustment. Steering: Handlebar and steering head bearing inspection and lubrication. Electrical System: Wiring diagrams, lighting systems, charging system (stator, regulator/rectifier), starter motor, battery maintenance. Frame And Body: Chassis inspection, body panel removal and installation, seat, fenders. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, chain adjustment. Troubleshooting: Diagnostic charts and procedures for common problems across all systems. Repair: Step-by-step repair instructions for all major components and systems. Rebuild: Complete engine and transmission rebuild procedures, including torque specifications and clearances. Inspection: Detailed inspection points for wear, damage, and proper function. Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls. Diagnostics: Includes diagnostic flowcharts and specific tests for electrical and mechanical components. Specifications: Extensive list of torque values, clearances, fluid capacities, electrical specifications, and tolerances. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Text-searchable PDF for quick information retrieval. Print Quality Quality: High-resolution scans suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, V-twin, air-cooled Displacement: 805 cc (49.1 cu in) Bore X Stroke: 83.0 mm x 74.4 mm (3.27 in x 2.93 in) Compression Ratio: 9.3:1 Performance Horsepower: Approximately 50 HP @ 6,500 RPM (Manufacturer estimate, may vary) Torque: Approximately 50 lb-ft @ 5,000 RPM (Manufacturer estimate, may vary) Fuel System Carburetion: Two Mikuni B27 constant velocity carburetors (e.g., VM31SS) Fuel Tank Capacity: 3.4 US gal (12.9 L) 🔧 Transmission Standard Type: 5-speed, constant mesh Clutch: Wet multi-plate Final Drive: Shaft drive Features Gear Ratios: Specific gear ratios are detailed within the manual for performance calculations and diagnostics. Transmission Fluid Type: Refer to manual for specific Suzuki or SAE 80W-90 gear oil recommendations. 📐 Dimensions Exterior Length: Approx. 91.7 in (2330 mm) Width: Approx. 36.2 in (920 mm) Height: Approx. 43.7 in (1110 mm) Weights Dry Weight: Approx. 485 lbs (220 kg) Gross Vehicle Weight Rating: Refer to manual for specific GVWR. Wheels And Tires Front Tire: MT90-16 (62H) Rear Tire: 170/80-15 (77H) Wheelbase: Approx. 63.0 in (1600 mm) Ground Clearance: Approx. 5.1 in (130 mm) 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles are not typically rated by agencies like NHTSA or IIHS in the same way as cars). Active Features Braking System: Disc front brake, Drum rear brake. Manual details performance characteristics and maintenance. Passive Features Lighting: Halogen headlight, taillight, brake light, turn signals. Electrical section covers bulb types and troubleshooting....