Suzuki VS800 Intruder 1992-2008 Service Manual

The VS800GL Intruder arrived in 1992 as a more accessible mid-size cruiser than the big VS1400, with an enlarged 805cc engine, a bigger radiator and larger forks over the 750 it replaced. It was sold as the Intruder 800 in North America, and for 2005 Suzuki relaunched its cruisers as Boulevards, renaming it the Boulevard S50 with updated graphics, minor electrical updates and different turn signals and switchgear. Mechanically it’s the same bike, so Intruder 800 and S50 parts swap across the years. The platform stayed largely unchanged through 2009, with the front wheel going from 21 inches in the 1990s to 19 inches from about 2000, so check the front wheel before ordering tires and parts.

Power comes from a liquid-cooled 805cc SOHC 45-degree V-twin with eight valves and TSCC heads, with an 83mm x 74.4mm bore and stroke and a 10:1 compression ratio. It makes about 48 hp at 7,000 rpm and 61 Nm of torque at 5,000 rpm. It’s fed by two carburetors, a Mikuni BDS36 at the front and a BS36 at the rear, which must be synchronized for smooth running, and an electric fuel pump on the Intruder. The gearbox is a 5-speed with shaft drive. Common issues include carburetor jets clogged by ethanol fuel, a cracked petcock diaphragm and corroded ground straps.

Brakes are a single hydraulic front disc and a rear drum. The 2000-2009 bikes use a 100/90-19 front tire and a 140/90-15 rear, with a 1,560mm (61.4-inch) wheelbase. The tank holds 12 litres (3.2 US gallons), or 11 litres on California bikes. Weight is about 228 kg, and average fuel economy is 38-46 mpg.

This factory service manual covers the procedures, torque specs, and diagrams needed to keep a Suzuki VS800 Intruder running the way it was built to.