2004-2009 Suzuki VZ800 Marauder Boulevard M50 Motorcycle Service Manual

Suzuki VZ800 Boulevard M50: Service Documentation Overview

• Covers 2004–2009 Suzuki VZ800, Marauder, and Boulevard M50 motorcycles with the 805cc V-twin engine and shaft drive system
• Official Suzuki publication P/N 99500-38050-01E, copyright 2004
• Contains 454 pages with hundreds of component exploded-view diagrams, torque specifications, and system-specific service tolerances
• Accessible from your device as soon as the order is placed
• OCR text layer lets you jump to a torque spec by keyword
• Suitable for printing individual sections for shop-floor use
• Permanent availability in your purchase account — no re-buy required
• This service volume serves as the primary technical reference for the full 2004–2009 VZ800 model production cycle

Detailed Technical Scope

This factory service manual provides extensive technical coverage for the Suzuki VZ800, Marauder, and Boulevard M50 line. Organized into 12 core groups, the content details disassembly, inspection, and assembly procedures for the 805cc liquid-cooled V-twin engine, shaft drive assembly, fuel injection system, and electrical components. The chapters provide specific guidance for periodic maintenance, chassis adjustments, and internal engine component tolerances including camshaft, piston, and crankshaft specifications.

Specification and Reference Highlights

Engine component data includes clearance tables for valve assemblies, piston ring-to-groove limits, and bearing thickness specifications. Torque values for critical fasteners are documented throughout, including cylinder head bolt specs (M6: 10 Nm; M8: 24.5 Nm) and oil drain plug settings of 21 Nm. The final gear oil volume is listed at 200–220 ml. Valve clearance for the intake is listed at 0.08–0.13 mm in the cylinder head specification table. Coolant system capacity for the VZ800 is documented at 1.5 liters total. The spark plug gap is specified at 0.8–0.9 mm in the maintenance data section. Additional data includes electrical connector pinouts, sensor thresholds for the FI system, and diagnostic code reporting procedures. Reference only — always consult a certified technician before performing service on this equipment.

An official 454-page Suzuki OEM service manual covering the 2004–2009 VZ800, Marauder, and Boulevard M50, documenting engine, chassis, electrical, and fuel-injection specifications for the complete multi-year build.