🏷️ Basic Information

Make:

Suzuki

Model:

VL800 Intruder Volusia

Year:

2006

Chassis Code:

WVBM

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Riders seeking a comfortable, stylish, and reliable cruiser for touring, commuting, and casual riding.

Key Competitors:

Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series, Harley-Davidson Sportster (smaller displacement models).

Styling:

Classic cruiser aesthetics with ample chrome, pulled-back handlebars, teardrop fuel tank, and a low seat height.

Engine Characteristics:

Torquey V-twin engine providing a relaxed riding experience and pleasant exhaust note.

Ride Comfort:

Designed for long-distance comfort with an upright riding position and plush seating.

Value Proposition:

Offers a strong balance of features, performance, and reliability at a competitive price point within its segment.

📋 Manual Details

Engines Covered:

1999cc V-twin, SOHC, 4-stroke, liquid-cooled

Transmission Covered:

5-speed constant mesh

Electrical System Covered:

Yes, comprehensive wiring diagrams and component testing

Bodywork And Frame Covered:

Yes, including disassembly, assembly, and repair procedures

Suspension Covered:

Yes, front telescopic forks and rear swingarm with adjustable shocks

Braking System Covered:

Yes, front disc, rear drum

Fuel System Covered:

Yes, including carburetor tuning and fuel pump diagnostics

Estimated Pages:

Approximately 300-400 pages (typical for a comprehensive service manual)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for top-end and bottom-end components, valve adjustments, timing chain inspection and replacement, piston and cylinder analysis, crankshaft and connecting rod checks.

Engine Electrical:

Ignition system troubleshooting, starter motor diagnosis, charging system analysis (alternator/stator, regulator/rectifier), CDI unit testing, sensor testing (TPS, MAP).

Fuel And Emissions:

Carburetor disassembly, cleaning, and reassembly; jetting information; idle speed adjustment; fuel delivery system checks; emissions control system components and function.

Transmission And Drivetrain:

Clutch inspection and adjustment, gear shift linkage troubleshooting, transmission component analysis, final drive lubrication and inspection.

Suspension And Steering:

Front fork seal replacement, oil level and type specifications, rear shock absorber adjustment and replacement, steering bearing inspection and lubrication.

Brakes:

Brake pad inspection and replacement, caliper servicing, master cylinder checks, brake fluid type and bleeding procedures, rear drum brake shoe adjustment.

Wheels And Tires:

Tire pressure specifications, tire wear analysis, wheel bearing inspection and replacement, spoke tension adjustment (if applicable to specific models).

Chassis And Frame:

Frame inspection for damage, headstock bearing replacement, swingarm bearing service.

Electrical Controls:

Handlebar switchgear troubleshooting, lighting system diagnostics, horn function, starter interlock circuits.

Cooling System:

Radiator inspection, coolant type and capacity, fan operation, thermostat testing.

Routine Maintenance:

Oil and filter changes, air filter service, spark plug replacement, chain adjustment and lubrication, brake fluid flush, coolant flush, lubrication points.

Troubleshooting Guides:

Systematic diagnostic charts for common and uncommon problems, symptom-based troubleshooting, fault code interpretation (if applicable).

Component Removal And Installation:

Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.

Engine Rebuilding:

Complete disassembly, cleaning, inspection, measurement, and reassembly procedures for engine internals.

Transmission Overhaul:

Detailed steps for gearbox disassembly, gear inspection, and reassembly.

Carburetor Synchronization:

Procedures for balancing multi-cylinder carburetors (though the VL800 is a twin, this skill is transferable and often included).

Electrical Diagnostics:

Wiring diagram interpretation, multimeter usage for testing circuits, component resistance and voltage checks.

Suspension Servicing:

Fork oil replacement, seal replacement, shock absorber adjustments.

Depth:

Comprehensive: Covers everything from basic owner maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and frame repairs. Suitable for professional technicians and advanced DIY mechanics.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format) - optimized for viewing and printing.

Print Readability:

High-resolution scans of original factory documentation, ensuring clear text, diagrams, and images.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format) - Users can print on their preferred paper stock.

Text Search:

Fully searchable text allows for quick access to specific topics, procedures, and specifications.

Hyperlinks:

Often includes internal links within the PDF for easy navigation between sections (depending on the source scan).

⚙️ Engine Specifications

Engine Type:

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

Displacement:

1999 cc (122 cubic inches)

Bore X Stroke:

76.0 mm x 64.0 mm

Compression Ratio:

9.2:1

Horsepower Est:

Approx. 60-65 HP (at crank)

Torque Est:

Approx. 90-95 Nm (at crank)

Fuel Delivery:

Two Mikuni B26 carburetors (CV type)

Fuel Tank Capacity:

15.5 L (4.1 US gal)

Ignition System:

Electronic ignition (CDI)

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Final Drive:

Shaft drive

Gear Ratios:

Refer to manual for specific gear ratios

Transmission Fluid Type:

API GL-5 SAE 80W-90 hypoid gear oil (typically for shaft drive, check manual for exact spec)

📐 Dimensions

Overall Length:

Approx. 2360 mm (92.9 in)

Overall Width:

Approx. 840 mm (33.1 in)

Overall Height:

Approx. 1100 mm (43.3 in)

Wheelbase:

Approx. 1655 mm (65.2 in)

Ground Clearance:

Approx. 135 mm (5.3 in)

Seat Height:

Approx. 700 mm (27.6 in)

Dry Weight:

Approx. 223 kg (492 lbs)

Curb Weight:

Approx. 237 kg (523 lbs) with fluids

Max Payload:

Refer to manual for specific payload capacity

🛡️ Safety Features

Safety Certifications:

Meets all applicable federal safety standards for motorcycles in its class (e.g., DOT, EPA).

Braking Performance:

Single disc front brake, drum rear brake provide adequate stopping power for its class. ABS was not a standard feature on this model.

Lighting:

Halogen headlight, tail light, and turn signals for good visibility.

Frame Construction:

Steel cradle frame designed for stability and rider support.

Ergonomics:

Low seat height and forward footpegs contribute to an accessible and controllable riding position for many riders.

💡 Technology Features

Audio System:

No integrated infotainment system; designed for a pure motorcycle experience.

Display:

Analog speedometer and tachometer, fuel gauge, indicator lights.

ABS:

Anti-lock Braking System (ABS) was not a standard or commonly available option for the 2006 VL800 Volusia.

Bluetooth:

No native Bluetooth connectivity.

Headlight Type:

Halogen

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 12 months, whichever comes first.

Valve Clearance Check:

Every 12,000 km (7,500 miles) or 24 months.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Air Filter Cleaning:

Every 6,000 km (3,700 miles), replace as needed.

Brake Fluid Change:

Every 24,000 km (15,000 miles) or 24 months.

Engine Oil Type:

Suzuki 4-stroke motorcycle oil, API SG/SH/SJ or higher, SAE 10W-40 (check manual for specific viscosity and API rating)

Engine Oil Capacity:

Approx. 2.6 L (2.7 US qt) without filter change, 2.8 L (3.0 US qt) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze solution (50% mixture with distilled water).

Fork Oil Type:

Suzuki SE 10W motorcycle fork oil (or equivalent with similar viscosity, check manual)

Fork Oil Quantity:

Approx. 308 ml (10.4 US oz) per fork leg.

Carburetor Cleaning:

Carburetors can require cleaning due to fuel deposits, especially if the bike sits for extended periods. The manual provides detailed procedures.

Shaft Drive Maintenance:

Regular inspection and lubrication of the shaft drive are crucial for longevity. The manual details the procedure and recommended lubricant.

Clutch Adjustment:

Clutch lever play may require periodic adjustment. The manual outlines the correct procedure.

Cooling System Leaks:

While generally reliable, hoses and connections should be inspected for potential leaks over time.

📚 Vehicle History

Manufacturer:

Suzuki Motor Corporation, a Japanese manufacturer known for a wide range of vehicles including motorcycles, automobiles, and marine engines.

Model Lineage:

The VL800 Intruder Volusia is part of Suzuki's Intruder line of cruisers, which has been a popular offering for decades. The Volusia was introduced as a larger displacement option in this line, emphasizing comfort and classic styling.

Production Start Year:

2001 (as the VL800 Intruder, later renamed Volusia)

Production End Year:

2004 for Volusia name, continued as Boulevard C50 from 2005 onwards.

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Market Reception:

Generally well-received by the motorcycling press and owners for its value, styling, and comfortable ride. Often praised as an excellent entry-level or mid-size cruiser.

Reliability:

Suzuki motorcycles are typically rated for good reliability, and the VL800 is no exception, provided regular maintenance is performed as outlined in the service manual.