Motorcycle Segment:
Cruiser
Target Audience:
Cruiser enthusiasts seeking classic styling and comfortable riding
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series
Engine Type:
V-twin cruiser engine
Styling:
Classic cruiser styling with flowing lines, teardrop fuel tank, and ample chrome
Covered Years:
2001, 2002, 2003, 2004, 2005, 2006
Market Coverage:
Primarily North America and Europe (based on Spanish language)
Estimated Page Count:
700-1000 (typical for factory service manuals of this era)
Manual Type:
Factory Service Manual (FSM)
Language:
Español (Spanish)
Engine Systems:
Engine mechanical, lubrication, cooling, fuel injection, ignition, starting, charging
Drivetrain Systems:
Transmission, clutch, final drive (shaft drive)
Chassis Systems:
Frame, suspension (front fork, rear shock), steering, wheels, tires
Braking Systems:
Front and rear brake systems (hydraulic)
Electrical Systems:
Wiring diagrams, lighting, battery, starter, alternator, sensors, ECU
Bodywork And Trim:
Body panels, fenders, seat, fuel tank, exhaust system
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid changes, fork oil changes
Repair Procedures:
Complete disassembly and reassembly of all major components and systems
Troubleshooting Diagnostics:
Diagnostic flowcharts, symptom analysis, fault code interpretation (if applicable to the era)
Technical Depth:
Comprehensive; covers routine maintenance to complete engine and transmission rebuilds
Diagnostic Focus:
Detailed diagnostics for fuel injection, ignition, and electrical systems
Special Tool Requirements:
Identifies specific Suzuki special tools required for certain procedures
Engine Type:
V-twin, 4-stroke, SOHC, 2 valves per cylinder
Engine Displacement:
805 cc (49.1 cu. in.)
Bore X Stroke:
83.0 mm x 74.4 mm (3.27 in. x 2.93 in.)
Cooling System:
Liquid-cooled
Horsepower Rating:
Approx. 50 HP (at crankshaft, varies by region/spec)
Torque Rating:
Approx. 65 Nm (48 lb-ft) (at crankshaft, varies by region/spec)
Fuel Delivery:
Fuel Injection (Suzuki's Dual Throttle Valve - SDTV system)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition System:
Electronic ignition (CDI)
Starting System:
Electric starter
Oil Type:
Suzuki recommends Suzuki Genuine Oil SAE 10W-40 API SG or higher
Overall Length:
Approx. 2370 mm (93.3 in.)
Overall Width:
Approx. 950 mm (37.4 in.)
Overall Height:
Approx. 1125 mm (44.3 in.)
Wheelbase:
Approx. 1655 mm (65.2 in.)
Ground Clearance:
Approx. 140 mm (5.5 in.)
Seat Height:
Approx. 700 mm (27.6 in.)
Dry Weight:
Approx. 216 kg (476 lbs)
Wet Weight:
Approx. 232 kg (511 lbs)
Fuel Capacity:
16.0 L (4.2 US gal)
Oil Capacity:
3.2 L (3.4 US qt) without filter change, 3.4 L (3.6 US qt) with filter change
Crash Test Ratings:
Motorcycles are not subjected to automotive-style crash testing or ratings.
Braking System Type:
Hydraulic disc brakes front and rear
ABS Availability:
ABS was not a standard or widely available option for this model year range.
Lighting:
Halogen headlight, LED taillight
Indicators:
Self-canceling turn signals
Oil And Filter Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first
Air Filter Inspection:
Inspect every 6,000 km (3,700 miles); clean/replace as needed
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles)
Brake Fluid Replacement:
Replace every 24,000 km (15,000 miles) or 2 years
Final Drive Oil Change:
Change every 12,000 km (7,500 miles)
Engine Oil Grade:
SAE 10W-40, API SG or higher
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based), 50% solution with distilled water
Final Drive Oil Type:
SAE 80W GL-5 gear oil
Common Wear Items:
Clutch plates, brake pads, tires, wheel bearings, throttle cables (due to cable routing)
Electrical Quirks:
Occasional issues with rectifier/regulator failure leading to charging problems (common across many bikes of this era); corroded grounds.
Engine Performance:
Fuel injection system generally robust, but check for proper idling and throttle response. Sensor failures (TPS, MAP) can occur.
Cooling System:
Leaks from radiator hoses or water pump seal can occur with age and mileage. Thermostat may fail.
Brand Focus:
Suzuki has a long history in motorcycle manufacturing, known for innovation in engines and chassis design across various segments.
Predecessor:
The VL800 Intruder was developed as a successor/evolution to earlier Suzuki cruisers, often drawing inspiration from classic American designs.
Key Design Aspects:
The 'Intruder' lineage often featured aggressive styling, while the 'Volusia' designation (used for some early models/markets) suggested a more classic, touring-oriented cruiser.
Production Period:
2001-2006 (covered by this manual)
Manufacturing Location:
Typically manufactured in Japan or, for some models, assembled in other Suzuki facilities globally.
