Suzuki VL800 Intruder 2001-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: VL800 Intruder Model Designation: Intruder Volusia Generation Generation Code: C50 Boulevard Codes Chassis Code: WVBM 👋 Introduction Market Position Segment: Cruiser Motorcycle Intended...

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UGS: 457204

Mots clés: 2001 2002 2003 2004 2005 2006 2007 2008 2009 Featured Intruder Motorcycle Motorcycles Suzuki VL800 Intruder

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VL800 Intruder

Model Designation:

Intruder Volusia

Generation

Generation Code:

C50 Boulevard

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Intended Use:

Cruising, touring, everyday riding.

Competitive Analysis

Key Competitors:

Honda Shadow, Yamaha V-Star, Kawasaki Vulcan.

Key Features

Engine Configuration:

V-twin, 45-degree cylinder angle.

Styling:

Classic cruiser aesthetics with flowing lines and chrome accents.

Handling Characteristics:

Comfortable and stable ride, suitable for longer distances.

Manual Value Proposition:

Enables owners to perform professional-level maintenance and repairs, saving on dealership costs.

📋 Manual Details

Coverage Areas

Model Years Covered:

2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, assembly, disassembly, lubrication system, fuel system, ignition system, exhaust system.

Transmission:

Gearbox disassembly and assembly, internal components, lubrication.

Electrical System:

Wiring diagrams, lighting, ignition, starting system, charging system, instrumentation.

Bodywork:

Frame, fairings, fenders, seat, controls, chassis components, removal and installation.

Suspension And Steering:

Front forks, rear shock absorbers, steering system, wheel alignment.

Braking System:

Brake fluid replacement, caliper overhaul, master cylinder, brake line maintenance.

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, lubrication, tune-ups, fluid checks.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding charts.

Repair:

Detailed step-by-step instructions for component repair and replacement.

Overhaul:

Complete disassembly and reassembly procedures for major components.

Installation Removal:

Procedures for removing and installing various parts and assemblies.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds.

Target Audience:

Professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Printable

Binding Type

Binding:

Digital (PDF)

Paper Type

Media:

Electronic Delivery via Email

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, V-twin, SOHC, 8-valve

Displacement:

805 cc (49.1 cu in)

Bore X Stroke:

83.0 mm x 75.0 mm

Cooling System:

Liquid-cooled

Compression Ratio:

9.3:1

Performance

Horsepower Estimate:

Approx. 53 hp @ 6,500 rpm (manufacturer data may vary)

Torque Estimate:

Approx. 70 Nm (52 lb-ft) @ 5,000 rpm (manufacturer data may vary)

Fuel System

Fuel Delivery:

Fuel Injection (Suzuki Dual Throttle Valve - SDTV)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

16.0 L (4.2 US gal)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch:

Wet multi-plate

Final Drive:

Shaft drive

Features

Gear Ratios:

Detailed in manual (e.g., 1st: 2.64, 2nd: 1.79, 3rd: 1.30, 4th: 1.04, 5th: 0.86)

📐 Dimensions

Exterior

Overall Length:

2,420 mm (95.3 in)

Overall Width:

925 mm (36.4 in)

Overall Height:

1,105 mm (43.5 in)

Wheelbase:

1,670 mm (65.7 in)

Ground Clearance:

135 mm (5.3 in)

Weights

Dry Weight:

214 kg (472 lbs)

Curb Weight:

231 kg (509 lbs)

Gross Vehicle Weight Rating:

Not specified, consult owner's manual or service manual.

🛡️ Safety Features

Ratings

Safety Certifications:

Meets relevant national and international motorcycle safety standards.

Active Features

Braking:

Front: Disc, Rear: Disc (some models may have variations)

Lighting:

Halogen headlight, LED tail light.

Passive Features

Frame Construction:

Steel frame for rigidity and stability.

Warning Symbols:

Manual utilizes WARNING, CAUTION, and NOTE designations for critical safety information.

💡 Technology Features

Infotainment

Audio System:

Not typically equipped with a factory-installed audio system.

Instrumentation:

Analog speedometer, tachometer, fuel gauge, indicator lights.

Driver Assistance

Not available on this model.

Connectivity

Charging Ports:

Optional accessory charging ports may be installed.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact details).

Spark Plug Replacement:

Refer to manual for mileage-based replacement intervals.

Chain Maintenance:

Not applicable, as the VL800 Intruder utilizes a shaft drive.

Fluid Specifications

Engine Oil Type:

API SG, SF, SE or higher, SAE 10W-40, JASO MA certified motorcycle oil (specific viscosity may vary based on climate).

Engine Oil Capacity:

Approx. 3.2 L (3.4 US qt) with filter change (refer to manual for precise capacity).

Brake Fluid Type:

DOT 4 brake fluid.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based, 50% mixture with distilled water).

Final Drive Oil Type:

Hypoid gear oil API GL-5, SAE 80W-90.

Known Issues

Common Wear Items:

Brake pads, tires, battery, clutch plates (depending on usage).

Potential Problems:

Fuel pump issues, stator coil failures (rare but documented), carburetor synchronization (if applicable on earlier models before fuel injection).

Special Tools

Required Tools:

Torque wrench, specific Suzuki factory tools (identified by numbers in the manual), standard metric toolset.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, a renowned Japanese manufacturer of automobiles and motorcycles.

Model Evolution

Predecessor:

VL1500 Intruder LC.

Rebranding:

In 2005, Suzuki rebranded the Intruder models under the 'Boulevard' name. The VL800 became the Boulevard C50.

Production

Production Period:

2001-2009 (for this specific manual coverage).

Manufacturing Location:

Japan (typically for Suzuki motorcycles).

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Consistently praised for its comfort, reliability, and classic styling within the cruiser segment.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to its dependable performance and user-friendly nature.