This manual covers the VS800GLY Intruder, a classic cruiser motorcycle produced in 2000. Renowned for its timeless design and the robust V-twin engine, the VS800GLY Intruder offers an accessible and enjoyable riding experience, fitting seamlessly into a heritage of reliable and performance-oriented motorcycles. Its engineering prioritizes comfortable cruising and a distinctive aesthetic, making it a popular choice among riders who appreciate traditional styling and dependable performance. This comprehensive service and repair manual provides detailed guidance for owners and technicians. It covers a wide array of essential areas, including engine mechanicals, fuel and ignition systems, transmission, chassis, brakes, and the electrical system. Within its approximately 300-400 pages, you will find procedures for scheduled maintenance, in-depth troubleshooting, and complete repair instructions for all major components. This resource is designed to empower users to maintain their VS800GLY Intruder effectively, ensuring its longevity and optimal performance. 🏷️ Basic Information Identification Make: Suzuki Model: VS800GLY Intruder Year: 2000 Codes Model Code: VS800GLY 👋 Introduction Market Position Category: Cruiser Motorcycle Target Audience: Owners of Suzuki VS800GLY Intruder, DIY mechanics, Service technicians Competitive Analysis Competitors: Honda Shadow VT600, Kawasaki Vulcan 750, Yamaha Virago XV750 Key Features Vehicle Design Philosophy: Classic cruiser styling with a V-twin engine, focus on accessible performance and comfortable riding. Key Features Manual Advantage Over Paper: Easily searchable, bookmarkable, printable sections, accessible on multiple devices, no wear and tear. 📋 Manual Details Coverage Areas Comprehensive Coverage: Engine, Transmission, Chassis, Electrical System, Bodywork, Maintenance, Troubleshooting, Specifications Page Count Estimated Page Count: 300-400 Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Top end (cylinder head, valves), Piston and connecting rod, Crankshaft, Camshafts, Lubrication system, Cooling system (air-cooled specifics) Fuel System: Carburetor(s) (Mikuni BSW 36), Fuel pump, Fuel tank, Fuel lines Ignition System: CDI, Ignition timing, Spark plugs Transmission Drivetrain: Clutch operation, Gearbox internals, Shift mechanism, Final drive (shaft drive components) Chassis Suspension: Front fork (telescopic), Rear suspension (swingarm, monoshock), Frame inspection and repair Brakes: Front disc brake (caliper, rotor, master cylinder), Rear drum brake (if applicable), Brake fluid specifications, Bleeding procedures Electrical System: Battery, Charging system (alternator, regulator/rectifier), Starter motor, Lighting system (headlight, taillight, turn signals), Wiring diagrams, Fuses, Relays Bodywork Styling: Body panels, Seat, Fuel tank removal/installation, Fenders, Handlebars Procedures Included Scheduled Maintenance: Oil changes, Filter replacement, Spark plug service, Air filter cleaning/replacement, Chain adjustment (if applicable, though shaft drive), Brake pad inspection/replacement, Coolant flush (if liquid-cooled), Valve clearance checks Troubleshooting: Diagnostic flowcharts, Common problem diagnosis (starting issues, misfires, electrical faults) Engine Repair: Engine disassembly and reassembly, Piston ring replacement, Valve seat grinding, Gasket replacement Transmission Repair: Gearbox overhaul, Clutch assembly replacement Suspension Repair: Fork seal replacement, Shock absorber replacement Electrical Diagnostics: Wiring harness repair, Component testing (stator, rectifier, starter) Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (OCR applied) Print Quality Quality: High resolution for clarity of diagrams and text Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, 2-valve-per-cylinder, SOHC V-twin Displacement: 797 cc (48.6 cu. in.) Bore X Stroke: 83.0 mm x 74.4 mm (3.27 in. x 2.93 in.) Compression Ratio: 9.2:1 Performance Horsepower Est: 50-55 HP (Approx.) Torque Est: 60-65 Nm (Approx.) Fuel System Carburetor Type: Single Mikuni BSW36 Fuel Capacity: 13.0 L (3.4 US gal) Lubrication Oil Type: SAE 10W-40 API SG or SH Oil Capacity W Filter: 2.5 L (2.6 US qt) Ignition Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in.) Ignition Timing Static: 10° BTDC 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-plate Features Final Drive: Shaft Drive Fluid Spec Transmission Oil: API GL-5 SAE 80W-90 Gear Oil Fluid Capacity Final Drive Oil Capacity: 100 ml (0.11 US qt) 📐 Dimensions Exterior Length: 2350 mm (92.5 in.) Width: 820 mm (32.3 in.) Height: 1160 mm (45.7 in.) Wheelbase: 1605 mm (63.2 in.) Ground Clearance: 135 mm (5.3 in.) Weights Dry Weight: 203 kg (447.5 lbs) Wet Weight Est: 220 kg (485 lbs) Tire Sizes Front Tire: 130/90-16M/C 67B Rear Tire: 170/80-15M/C 77P Wheel Specs Front Wheel Type: Cast aluminum Rear Wheel Type: Cast aluminum 🛡️ Safety Features Ratings Safety Certification: DOT, ECE (as applicable for markets) Active Features Braking System: Front disc, Rear drum (typically) Passive Features Lighting: Halogen headlight, LED taillight (common for cruisers) 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, odometer, neutral indicator, high beam indicator). No advanced infotainment systems. Driver Assistance Features: None (typical for this era of cruiser). Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km (1,800-3,000 miles) or 6 months Valve Clearance Check: Every 10,000-15,000 km (6,000-9,000 miles) Spark Plug Replacement: Every 15,000-20,000 km (9,000-12,000 miles) Fluid Specifications Brake Fluid: DOT...