Introduction
This Clymer repair manual, model 27-M481, provides comprehensive maintenance, troubleshooting, and repair information for Suzuki VS700-800 Intruder and Boulevard S50 motorcycles manufactured between 1985 and 2009. It is designed to assist both professional mechanics and do-it-yourself enthusiasts in performing various service procedures.
Image: Front cover of the Clymer Repair Manual for Suzuki VS700-800 Intruder and Boulevard S50 models. The cover displays the Clymer logo, the manual's model number M481-6, and an image of a Suzuki Intruder motorcycle. Text on the cover indicates it covers "Maintenance • Troubleshooting • Repair" for models from 1985-2009.
Product Overview
The Clymer M481-6 manual is a detailed shop service manual specifically tailored for the Suzuki Intruder and Boulevard S50 series. It includes step-by-step instructions, diagrams, and illustrations to guide users through various repair and maintenance tasks, from routine service to major overhauls.
Covered Models and Years:
- VS700 Intruder (U.S.): 1986-1987
- VS750 Intruder (U.S.): 1988-1991
- VS800 Intruder (U.S.): 1992-2004
- VS800 Boulevard S50: 2005-2009
- VS750 (U.K.): 1985-1991
- VS800 (U.K.): 1992-1997
Using Your Repair Manual
Before beginning any repair or maintenance task, it is recommended to thoroughly read the relevant sections of this manual. Ensure you have a clean, well-lit workspace and all necessary tools and replacement parts. Safety precautions outlined in the manual should always be followed.
Preparation Steps:
- Review Safety Information: Always begin by understanding the safety warnings and precautions specific to the motorcycle and the procedures you intend to perform.
- Identify the Correct Section: Locate the chapter and section pertaining to the specific component or system you are working on.
- Gather Tools and Materials: Collect all required tools, lubricants, and replacement parts as specified in the manual for the task.
- Understand Diagrams and Illustrations: Pay close attention to exploded views, wiring diagrams, and other illustrations, as they provide critical visual guidance.
Navigating the Manual
The manual is organized into chapters, each covering a major system or component of the motorcycle. Within each chapter, specific procedures are detailed step-by-step. Use the chapter titles and headings to quickly locate the information you need.
Key Navigation Tips:
- Chapter Structure: Chapters typically cover topics such as engine, transmission, fuel system, electrical system, brakes, suspension, and chassis.
- Step-by-Step Procedures: Most repair and maintenance tasks are broken down into numbered steps, often accompanied by corresponding images.
- Specifications and Torque Values: Important specifications, including fastener torque values, are usually found at the beginning or end of relevant sections.
- Troubleshooting Charts: Dedicated sections or charts assist in diagnosing common problems based on symptoms.
Maintenance Procedures
This manual provides detailed instructions for routine maintenance tasks essential for the longevity and performance of your Suzuki Intruder/Boulevard S50. Regular maintenance helps prevent major issues and ensures safe operation.
Examples of Covered Maintenance:
- Oil and filter changes
- Spark plug inspection and replacement
- Air filter cleaning/replacement
- Brake system inspection and fluid replacement
- Tire inspection and pressure checks
- Chain/shaft drive lubrication and adjustment (if applicable)
- Coolant system checks
- General fastener torque checks
Troubleshooting Guide
The troubleshooting section of this manual is designed to help identify the root cause of common operational issues. It typically presents symptoms and guides you through a logical diagnostic process to pinpoint the problem before attempting repairs.
Common Troubleshooting Areas:
- Engine starting difficulties
- Poor engine performance
- Electrical system malfunctions (e.g., lights, charging)
- Brake system issues
- Suspension and steering problems
- Unusual noises or vibrations
Manual Specifications
Below are the physical specifications of the Clymer 27-M481 Repair Manual:
| Attribute | Value |
|---|---|
| Manufacturer | Clymer |
| Brand | Clymer |
| Model | Clymer 27-M481 |
| Item Weight | 1.8 pounds |
| Product Dimensions | 10 x 7 x 0.2 inches |
| Item Model Number | CM481-6 |
| Manufacturer Part Number | M481-6 |
| UPC | 024185954569 |
| Date First Available | May 3, 2012 |
Warranty and Support
This document is a repair manual providing detailed instructions for motorcycle maintenance and repair. For specific warranty information regarding the Clymer repair manual itself, please refer to the publisher's official website or contact Clymer customer support directly. For support related to the motorcycle models covered, please consult an authorized Suzuki dealership or service center.
