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Suzuki

Suzuki VL800 Intruder 2001-2009 Workshop Service Repair Manual

Suzuki VL800 Intruder 2001-2009 Workshop Service Repair Manual

$16.99
$16.99
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Toimituskulut lasketaan kassalla.
Vehicle data plateRef 457204
Brand
Suzuki
Vehicle
Motorcycle
Models covered
Intruder, Motorcycles, VL800 Intruder
Years
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
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  • Not sure it covers your model year? Ask us before you buy
🏷️ 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 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:
638
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 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:
PDF
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
ABS:
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.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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