2004-2008 Suzuki VZ1600 Marauder Shop Manual

Technical reference for the VZ1600 Marauder. Documents engine, fuel, and cooling systems for efficient maintenance. PN 99500-39261-01E.

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Document Details

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Document Number / Seller:
24640 / Jessica Wilson
File Size:
21.69 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 22, 2025

Models Covered & Key Technical Specifications

Suzuki VZ1600 Marauder / Boulevard M95 (99500-39261-01E) – 2004-2008 edition

Reference data & procedures | Motorcycle Portfolio Package.

  • Measured Engine Type: V2-cylinder signifies the engine's core architecture.
  • Fundamental Displacement: For optimal operation, 1552 mL defines the engine capacity Framework.
  • Baseline Compression Ratio: 9.0:1 -- signifies the standard compression threshold.
  • Integral Bore and Stroke: The cylinders require 102 x 95 mm for standard operation Logic.
  • Operational Cooling System: Liquid-cooled signifies the cooling system's efficiency Parameters.
  • Published Ignition Timing: Electronically advanced specifies the timing configuration.

Professional Workshop Service Manual & Technical Specifications

Comprehensive Operations Repair Manual: Suzuki VZ1600 Marauder Shop-Grade manual, 2004-2008 edition Wiring-Compendium

Engineering-Metrics: VZ1600 / Year-Coverage: 2004-2008 / Engineering-Metrics: Motorcycle

Integrated-Framework Value Logic
Engine Type 4-stroke, SOHC, V2-cylinder Standard
Cooling System Liquid-cooled Standard
Ignition System Battery and coil (transistorized) Standard

Engineering chapters address:

Fuel System

This section details the Fuel Injection System, including throttle sensor and air pressure sensor inspections, fuel pump operation, and injector testing procedures. It outlines troubleshooting for various service codes.

Cooling System

This manual documents the cooling system, covering coolant specifications, water pump removal/installation, radiator inspection, and thermostat testing. Procedures for hose and pipe maintenance are included.

Engine Top End

Information on engine top end components is provided, including camshafts, rocker arms, cylinder heads, valves, and pistons. It details removal, installation, inspection, and wear checks for these parts.

DFI System Troubleshooting

This section guides users through troubleshooting the Digital Fuel Injection system, covering self-diagnosis, service code reading, and specific component checks like sensors and ignition coils.

Exhaust System

Procedures for exhaust pipe removal and installation, muffler maintenance, and chamber inspections are outlined to ensure optimal performance and emissions.

Troubleshooting

This manual documents torque specifications for [component] to ensure service interval reliability.

FAQ

Determine the **specific** torque specifications for the VZ1600? keyboard_arrow_down

115 N·m is listed as the standard torque for the Cylinder Head Nuts, crucial for proper engine assembly.

What **designated** safety precautions are outlined? keyboard_arrow_down

16 N·m is specified for the Air Cleaner Cover Allen Bolt, with a caution to ensure proper seating and avoid damage.

Check the **critical** lubrication requirements for the engine? keyboard_arrow_down

Molybdenum disulfide oil is recommended for the Rocker Shafts and Camshaft Sprocket Bolts to ensure proper operation and longevity.

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This shop manual made my maintenance tasks so much easier! The sections are well-organized and easy to follow. Plus, the download process was smooth, and I received the link quickly after purchase. Highly recommend!