2004-2009 Suzuki VZ800 Marauder Boulevard M50 Motorcycle Service Manual

Wiring diagrams, specifications, and repair sequences for the VZ800 with detailed procedures for engine, chassis, and electrical systems. Ref: 99500-38050-01E

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Document Details

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Document Number / Seller:
30889 / Donna Morris
File Size:
19.92 MB
File Type:
PDF
Language:
English
Pages:
454
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Apr 4, 2025

Models Covered & Key Technical Specifications

Suzuki VZ800, Marauder, Boulevard M50 Service Manual: Suzuki VZ800, Marauder, Boulevard M50 Motorcycle Service Manual 2004-2009 - Complete Guide

Model-Specs: VZ800 / Marauder / Boulevard M50 (2004-2009) // Operational-Framework: Motorcycle / Standard Logic // Service-Level: Comprehensive Repair & Maintenance Procedures

  • Factory RPM Specs: 1100 ± 100 r/min is the specified idle speed Baseline.
  • Essential Weight Data: 247 kg (545 lbs) establishes the dry mass Requirements.
  • Key Resolution Data: 140 mm (5.5 in) is the specified ground clearance Benchmarks.
  • Verified Twist Specifications: 170/80-15M/C (77H) defines the rear tire size Sequences.
  • Designated Deviation Limits: 33° 15’ is the specified caster angle Threshold.
  • Approved Throughput Data: 15.0 L (4.0/3.3 US/Imp gal) is the fuel tank capacity Range.

Professional Workshop Service Manual & Technical Specifications

Suzuki VZ800, Marauder, Boulevard M50 Service Manual: Suzuki VZ800, Marauder, Boulevard M50 Motorcycle Service Manual 2004-2009 - Complete Guide

Model-Specs: VZ800 / Marauder / Boulevard M50 (2004-2009) // Operational-Framework: Motorcycle / Standard Logic // Service-Level: Comprehensive Repair & Maintenance Procedures

Procedures Cooling system maintenance is addressed in sections detailing coolant level checks and coolant changes, including air bleeding procedures. Brake system maintenance covers front and rear brake inspections, adjustments, and fluid level checks. Chassis maintenance involves checks on tires, steering, front fork, rear suspension, and chassis bolts. Electrical system checks include ignition, spark plug, battery, generator, fuses, and lighting components. Detailed procedures are provided for engine oil and filter changes, idle speed adjustments, throttle cable play, clutch adjustments, and final gear oil replacement.

Specifications This manual documents specifications for engine components such as bore, stroke, displacement, and compression ratio. It details drive train specifications including clutch type, transmission, gear ratios, and final reduction ratio. Chassis specifications cover suspension, brakes, tires, steering, and electrical system components. Capacities for fuel tank, engine oil, and coolant are also listed.

Systems The manual details the FI system, including technical features, compensation of injection time, and injection stop control. It covers troubleshooting procedures, self-diagnosis functions, and SDS diagnostic procedures. Troubleshooting steps are provided for various malfunction codes related to sensors, ignition system, and fuel system components. The manual includes detailed explanations of each system, such as the intake air pressure sensor, throttle position sensor, and engine coolant temperature sensor.

Table Integrated-Framework System-Path Logic
Engine Specs Drive Train Performance
Chassis Specs Electrical Operation
FI System Troubleshooting Diagnostics
Shaft Drive Maintenance Component
Periodic Maint. Engine Oil Lubrication

Torque Statement This manual documents torque specifications for engine mounting bolts and crankshaft components to ensure proper bearing preload accuracy.

Table of Contents Summary Reference chapters include: General Information, Periodic Maintenance, Engine, Shaft Drive, FI System, and Electrical Circuit Inspection Procedures. Each section provides in-depth coverage of specific motorcycle systems and components, with detailed procedures for inspection, maintenance, and repair. The manual offers a structured approach to understanding and servicing the Suzuki VZ800.

FAQ

Assess the **critical** calibration settings for engine performance. keyboard_arrow_down

1100 ± 100 r/min is the specified idle speed for optimal engine operation.

What components **required** clearance measurements are detailed? keyboard_arrow_down

Clearance measurements for valve mechanisms, including intake and exhaust valves, are addressed for proper engine function.

Confirm the **specified** torque specifications for engine reassembly. keyboard_arrow_down

23 N·m is the specified torque for the secondary gear case bolts and secondary driven bevel gear bolts.

What tools **essential** safety precautions are highlighted? keyboard_arrow_down

Special tools are essential for tasks like removing circlips and bearings, with warnings about handling gasoline and the importance of using new seals to prevent oil leakage.

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This manual is a lifesaver! The instructions are clear and easy to follow. I was able to perform maintenance on my motorcycle without any issues. Highly recommend for both newbies and experienced mechanics!