Suzuki Intruder VL800 User manual

IMPORTANT
 WARNING/  CAUTION/
NOTICE /NOTE
Please read this manual and fol-
low its instructions carefully. To
emphasize special information,
the symbol and the words
WARNING, CAUTION, NOTICE
and NOTE have special mean-
ings. Pay particular attention to
messages highlighted by these
signal words:
NOTE: Indicates special informa-
tion to make maintenance easier
or instructions clearer.
FOREWORD
Motorcycling is one of the most
exhilarating sports and to ensure
your riding enjoyment, you should
become thoroughly familiar with
the information presented in this
Owner’s Manual before riding the
motorcycle.
The proper care and maintenance
that your motorcycle requires is
outlined in this manual. By follow-
ing these instructions explicitly
you will ensure a long trouble-free
operating life for your motorcycle.
This motorcycle also conforms to
the U.S. Environmental Protection
Agency (EPA) and California Air
Resource Board (CARB) emis-
sion regulations which apply to
new motorcycles. The proper
adjustment of engine components
is necessary for this motorcycle to
comply with the EPA and CARB
regulations. Therefore, please fol-
low the maintenance instructions
closely to ensure emission com-
pliance. Your authorized Suzuki
dealer has experienced techni-
cians that are trained to provide
your machine with the best possi-
ble service with the right tools and
equipment.
WARNING
Indicates a potential hazard
that could result in death or
serious injury.
CAUTION
Indicates a potential hazard
that could result in minor or
moderate injury.
NOTICE
Indicates a potential hazard
that could result in vehicle or
equipment damage.

All information, illustrations, and
specifications contained in this
manual are based on the latest
product information available at
the time of publication. Due to
improvements or other changes,
there may be some discrepan-
cies between information in this
manual and your motorcycle.
Suzuki reserves the right to make
production changes at any time,
without notice and without incur-
ring any obligation to make the
same or similar changes to vehi-
cles previously built or sold.
Suzuki Motor Corporation
believes in conservation and pro-
tection of Earth’s Natural
resources. To that end, we
encourage every vehicle owner to
recycle, trade in, or properly dis-
pose of, as appropriate, used
motor oil, engine coolant, and
other fluids, batteries, and tires.

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
10
THE SPORT OF MOTORCYCLING
FUEL, OIL AND COOLANT RECOMMENDATIONS
CONTROLS, EQUIPMENT AND ADJUSTMENTS
BREAK-IN AND INSPECTION BEFORE RIDING
RIDING TIPS
ACCESSORY USE AND MOTORCYCLE LOADING
INSPECTION AND MAINTENANCE
TROUBLESHOOTING
STORAGE PROCEDURE AND MOTORCYCLE CLEANING
CONSUMER INFORMATION
SPECIFICATIONS
INDEX

1-1
1
THE SPORT OF MOTORCYCLING
MOST ACCIDENTS CAN BE AVOIDED ............................................................. 1-2
IF YOU DON’T HAVE A HELMET - BUY A HELMET, AND
WEAR IT EVERY TIME YOU RIDE ..................................................................... 1-3
IF A COLLISION IS IMMINENT, DO SOMETHING! ........................................... 1-3
SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......................................... 1-4
KNOW YOUR LIMITS .......................................................................................... 1-5
BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS ........................ 1-5
PRACTICE AWAY FROM TRAFFIC ................................................................... 1-6
INSPECTION BEFORE RIDING .......................................................................... 1-6
ACCESSORIES AND LOADING ......................................................................... 1-6
CARRYING A PASSENGER ............................................................................... 1-6
MOTORCYCLE SAFETY FOUNDATION’S
“RIDING TIPS AND PRACTICE GUIDE” HANDBOOK
(FOR OWNERS IN USA) ..................................................................................... 1-7
BE STREET SMART ........................................................................................... 1-7
LABELS ............................................................................................................... 1-7
CONCLUSION ..................................................................................................... 1-7

1-2
THE SPORT OF
MOTORCYCLING
Your motorcycle and this owner’s
manual have been designed by
people like you who enjoy motor-
cycling. People become motorcy-
clists for many reasons. For
starters, street riding is fun and
invigorating. But no matter why
you became a motorcyclist, or
how experienced you are, you will
eventually face some challenging
situations.
In preparing for these challenges,
you will be fine-tuning your coordi-
nation, concentration, and atti-
tude. Learning the skills and
strategies associated with motor-
cycling is the basis for safely par-
ticipating in this sport. Many
motorcyclists find that as they
become better riders, they also
get more enjoyment from the free-
dom unique to motorcycling.
Please remember:
MOST ACCIDENTS CAN BE
AVOIDED
The most common type of motor-
cycle accident in the U.S. occurs
when a car traveling toward a
motorcycle turns left in front of the
motorcycle. Is that because other
drivers are out to get motorcy-
clists? No. Other drivers simply
don’t always notice motorcyclists.
Ride defensively. Wise motorcy-
clists use a strategy of assuming
they are invisible to other drivers,
even in broad daylight. Pay care-
ful attention to other motorists,
especially at intersections,
because they may not be paying
attention to you. Select a lane
position that gives you the best
view of others, and other motor-
ists the best view of you. Wear
bright, reflective clothing. Put
reflective strips on your helmet.

1-3
IF YOU DON’T HAVE A
HELMET - BUY A HELMET, AND
WEAR IT EVERY TIME YOU RIDE
Most accidents occur within a few
miles of home, and almost half
occur at speeds of less than 30
mph. So even if you’re just going
on a quick errand, be prepared-
strap on your helmet before you
take off.
Helmets do not reduce essential
vision or hearing. Generally, hel-
mets do not cause or intensify
injury if you crash. Helmets simply
help your skull protect your intelli-
gence, your memory, your per-
sonality, and your life.
Your eyesight is equally valuable.
Wearing suitable eye protection
can help keep your vision
unblurred by the wind and save
your eyes from airborne hazards
like bugs, dirt, or pebbles kicked
up by tires.
IF A COLLISION IS IMMINENT,
DO SOMETHING!
Many riders fear locking up their
brakes or haven’t learned to
swerve to avoid an accident.
Many inexperienced riders (and
too many seasoned riders) use
only their rear brake in an emer-
gency, resulting in unnecessary
impacts in some cases and
unnecessarily high impact speeds
in other cases. Your rear brake
can only provide about 30% of
your motorcycle’s potential stop-
ping power. The front and rear
brakes can and should be used
together to maximize braking
effectiveness.
Experienced motorcyclists learn
to “cover” the front brake lever by
lightly resting a couple of fingers
over the lever when riding in traffic
and near intersections to give
their reaction time a head start.

1-4
Emergency stopping and swerv-
ing are techniques that you
should practice and master before
you find yourself in an emergency
situation. The best place to prac-
tice such techniques is in a con-
trolled environment such as the
Motorcycle Safety Foundation’s
(MSF) rider training courses. The
MSF’s Motorcycle Rider Courses
(fundamental techniques) and
Experienced Rider Courses
(advanced strategies) present
hands-on instruction of the basic
principles of motorcycling and a
variety of accident avoidance
maneuvers. Even a seasoned
motorcyclist can improve his or
her riding skills, and pick up a few
new skills, through these courses.
Some insurance companies even
offer discounts to course gradu-
ates.
SPECIAL SITUATIONS REQUIRE
SPECIAL CARE
Of course, there are some times
when full-force braking is not the
correct technique. When the road
surface is wet, loose, or rough,
you should brake with care. When
you’re leaned over in a corner,
avoid braking. Straighten up
before braking. Better yet, slow
down before entering a corner.
In these situations, the traction
available between your tires and
the road surface is limited. Over-
braking when traction is limited
will cause your tires to skid, possi-
bly resulting in loss of directional
control or causing you and your
motorcycle to fall over.

1-5
KNOW YOUR LIMITS
Always ride within the boundaries
of your own skills. Knowing these
limits and staying within them will
help you avoid accidents.
A major cause of accidents involv-
ing only a motorcycle (and no
cars) is going too fast through a
turn. Before entering a turn, select
an appropriately low cornering
speed.
Even on straight roads, ride at a
speed that is appropriate for the
traffic, visibility and road condi-
tions, your motorcycle, and your
experience.
Riding a motorcycle safely
requires that your mental and
physical skills are fully part of the
experience. You should not
attempt to operate a motor vehi-
cle, especially one with two
wheels, if you are tired or under
the influence of alcohol or other
drugs. Alcohol, illegal drugs, and
even some prescription and over-
the-counter drugs can cause
drowsiness, loss of coordination,
loss of balance, and especially
the loss of good judgment. If you
are tired or under the influence of
alcohol or other drugs, PLEASE
DO NOT RIDE your motorcycle.
BE EXTRA SAFETY-CONSCIOUS
ON BAD WEATHER DAYS
Riding on bad weather days,
especially wet ones, requires
extra caution. Braking distances
increase on a rainy day. Stay off
the painted surface marks, man-
hole covers, and greasy appear-
ing areas, as they can be
especially slippery. Use extra cau-
tion at railway crossings and on
metal gratings and bridges. When
it starts to rain, any oil or grease
on the road rises to the surface of
the water. Pull over and wait a few
minutes until this oil film is
washed away before riding.
Whenever in doubt about road
conditions, slow down!

1-6
PRACTICE AWAY FROM TRAFFIC
Your riding skill and your mechan-
ical knowledge form the founda-
tion for safe riding practices. We
suggest that you practice riding
your motorcycle in a nontraffic sit-
uation until you are thoroughly
familiar with your machine and its
controls. Again, consider taking
one of the MSF’s Rider Courses.
Even experts will be pleased with
the caliber of the information pre-
sented in these courses. As the
MSF says: “The more you know,
the better it gets!”
INSPECTION BEFORE RIDING
Review the instructions in the
INSPECTION BEFORE RIDING
section of this manual. Perform an
entire pre-ride inspection before
you head out on the road. Spend-
ing a few minutes preparing your
machine for a ride can help pre-
vent accidents due to mechanical
failure or costly, inconvenient
breakdowns far from home.
ACCESSORIES AND LOADING
The accessories you use with your
motorcycle and the manner in
which you load your gear onto the
bike might create hazards. Aerody-
namics, handling, balance, and
cornering clearance can suffer,
and the suspension and tires can
be overloaded. Read the ACCES-
SORY USE AND MOTORCYCLE
LOADING section.
CARRYING A PASSENGER
Carrying a passenger, when done
correctly, is a great way to share
the joy of motorcycling. You will
have to alter your riding style
somewhat since the extra weight
of a passenger will affect handling
and braking. You may also need
to adjust tire pressures and sus-
pension; please refer to the Tire
Pressure and Loading section
and the Suspension section for
more details.
A passenger needs the same pro-
tection that you do, including a
helmet and proper clothing. The
passenger should not wear long
shoe laces or loose pants that
could get caught in the wheel or
the chain. Passengers must be
tall enough that their feet reach
the footrests.

1-7
MOTORCYCLE SAFETY
FOUNDATION’S
“RIDING TIPS AND PRACTICE
GUIDE” HANDBOOK
(FOR OWNERS IN USA)
This special handbook, supplied
with your owner’s manual, con-
tains a variety of safety tips, help-
ful hints, and practice exercises.
This manual can increase your
riding enjoyment and safety. You
should read it thoroughly.
BE STREET SMART
Always heed speed limits, local
laws, and the basic rules of the
road. Set a good example for oth-
ers by demonstrating a courteous
attitude and a responsible riding
style.
LABELS
Read and follow all the labels on
the motorcycle. Make sure you
understand all of the labels. Do
not remove any labels from the
motorcycle.
CONCLUSION
Traffic, road and weather condi-
tions vary. Other motorist’s
actions are unpredictable. Your
motorcycle’s condition can
change. These factors can best
be dealt with by giving every ride
your full attention.
Circumstances beyond your con-
trol could lead to an accident. You
need to prepare for the unex-
pected by wearing a helmet and
other protective gear, and learn-
ing emergency braking and
swerving techniques to minimize
the damage to you and your
machine.
The best way to learn basic riding
skills and evasive maneuvers or
refresh your own riding skills is to
take one of the courses offered by
the Motorcycle Safety Foundation.
Your authorized Suzuki dealer
can help you locate the funda-
mental or advanced riding skills
course nearest you, or owners in
the USA can call toll-free 1-800-
446-9227.
Good riding on your new Suzuki!

2-1
2
FUEL, OIL AND COOLANT
RECOMMENDATIONS
FUEL .................................................................................................................... 2-2
ENGINE OIL ......................................................................................................... 2-4
GEAR OIL ............................................................................................................ 2-5
ENGINE COOLANT SOLUTION ......................................................................... 2-6

2-2
FUEL, OIL AND
COOLANT
RECOMMENDATIONS
FUEL
Your motorcycle requires regular
unleaded gasoline with a mini-
mum pump octane rating of 87
((R+M)/2 method). In some areas,
the only fuels that are available
are oxygenated fuels.
NOTE:
• If the engine develops some
trouble like lack of acceleration
or insufficient power, the cause
may be due to the fuel the
motorcycle uses. In such case,
try changing to a different gas
station. If the situation is not
improved by changing, consult
your Suzuki dealer.
• If pinking or knocking is experi-
enced, substitute higher
octane grade gasoline or
another brand, because there
are differences between
brands.
Oxygenated fuels which meet the
minimum octane requirement and
the requirements described below
may be used in your motorcycle
without jeopardizing the New
Vehicle Limited Warranty or the
Emission Control System War-
ranty.
NOTE: Oxygenated fuels are
fuels which contain oxygen-carry-
ing additives such as alcohol.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and
ethanol (grain alcohol), also
known as GASOHOL, are com-
mercially available in some areas.
Blends of this type may be used in
your motorcycle if they are no
more than 10% ethanol. Make
sure this gasoline-ethanol blend
has octane ratings no lower than
those recommended for gasoline.
Use the recommended gasoline.
or

2-3
Fuel Pump Labeling
In some states, pumps that dis-
pense oxygenated fuels are
required to be labeled for the type
and percentage of oxygenate, and
whether important additives are
present. Such labels may provide
enough information for you to
determine if a particular blend of
fuel meets the requirements listed
above. In other states, pumps
may not be clearly labeled as to
the content or type of oxygenate
and additives. If you are not sure
that the fuel you intend to use
meets these requirements, check
with the service station operator
or the fuel supplier.
NOTE:
• To help minimize air pollution,
Suzuki recommends that you
use oxygenated fuels.
• Be sure that any oxygenated
fuel you use has octane rat-
ings of at least 87 pump
octane ((R+M)/2 method).
• If you are not satisfied with the
drivability of your motorcycle
when you are using an oxy-
genated fuel, or if engine ping-
ing is experienced, substitute
another brand as there are dif-
ferences between brands.
NOTICE
Spilled gasoline containing
alcohol can damage the
painted surfaces of your
motorcycle.
Be careful not to spill any fuel
when filling the fuel tank. Wipe
spilled gasoline up immedi-
ately.

2-4
ENGINE OIL
Suzuki recommends the use of
SUZUKI PERFORMANCE 4
MOTOR OIL or equivalent engine
oil. If SUZUKI PERFORMANCE 4
MOTOR OIL is not available,
select a proper engine oil accord-
ing to the following guideline.
Oil quality is a major contributor to
your engine’s performance and
life. Always select good quality
engine oil. Use oil with an API
(American Petroleum Institute)
classification of SG, SH, SJ, SL,
SM or SN with a JASO classifica-
tion of MA.
API: American Petroleum Institute
JASO: Japanese Automobile
Standards Organization
NOTE: SUZUKI highly recom-
mends the use of ECSTAR brand
engine oil. ECSTAR has been
specially formulated for your
SUZUKI product and contributes
to the desired motorcycle perfor-
mance and ideal riding experi-
ence.
SAE Engine Oil Viscosity
Suzuki recommends the use of
SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available,
select an alternative according to
the following chart.
* USE ONLY SG, SH, SJ or SL.
JASO T903
The JASO T903 standard is an
index to select engine oils for 4-
stroke motorcycle and ATV
engines. Motorcycle and ATV
engines lubricate clutch and
transmission gears with engine
oil. JASO T903 specifies perfor-
mance requirements for motorcy-
cle and ATV clutches and
transmissions.
There are two classes, MA and
MB. The oil container shows the
classification as follows.
1Code number of oil sales company
2Oil classification
SAE API JASO
10W-40 SG, SH, SJ, SL,
SM or SN MA
ENGINE OIL
TEMP.

2-5
Energy Conserving
Suzuki does not recommend the
use of “ENERGY CONSERVING”
or “RESOURCE CONSERVING”
oils. Some engine oils which have
an API classification of SH, SJ,
SL, SM or SN have an “ENERGY
CONSERVING” or “RESOURCE
CONSERVING” indication in the
API classification donut mark.
These oils can affect engine life
and clutch performance.
API SG, SH, SJ, SL, SM or SN
Recommended
API SH, SJ, SL or SM API SN
Not recommended
GEAR OIL
Use an SAE90 hypoid gear oil
which is rated GL-5 under the API
classification system. If you oper-
ate the motorcycle where ambient
temperature is below 0°C (32°F),
use SAE80 hypoid gear oil.
A
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2-6
ENGINE COOLANT SOLUTION
Use “SUZUKI SUPER LONG
LIFE COOLANT” or “SUZUKI
LONG LIFE COOLANT”. If
“SUZUKI SUPER LONG LIFE
COOLANT” and “SUZUKI LONG
LIFE COOLANT” are not avail-
able, use a glycol-based anti-
freeze compatible with an
aluminum radiator mixed with dis-
tilled water only at the ratio of
50:50.
NOTE: SUZUKI highly recom-
mends the use of ECSTAR brand
coolant. ECSTAR has been spe-
cially formulated for your SUZUKI
product and contributes to the
desired motorcycle performance
and ideal riding experience.
WARNING
Engine coolant is harmful or
fatal if swallowed or inhaled.
Solution can be poisonous to
animals.
Do not drink antifreeze or cool-
ant solution. If swallowed, do
not induce vomiting. Immedi-
ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Keep out of the
reach of children and animals.
NOTICE
Spilled engine coolant can
damage the painted surfaces of
your motorcycle.
Be careful not to spill any fluid
when filling the radiator. Wipe
spilled engine coolant up
immediately.

2-7
ENGINE COOLANT
Engine coolant performs as a rust
inhibitor and water pump lubricant
as well as an anti-freeze solution.
Therefore engine coolant should
be used at all times even though
the atmospheric temperature in
your area does not go down to the
freezing point.
SUZUKI SUPER LONG LIFE
COOLANT (Blue)
“SUZUKI SUPER LONG LIFE
COOLANT” is pre-mixed to the
proper ratio. Add only “SUZUKI
SUPER LONG LIFE COOLANT”
if coolant level drops. It is not nec-
essary to dilute “SUZUKI SUPER
LONG LIFE COOLANT” when
replacing coolant.
SUZUKI LONG LIFE COOLANT
(Green)
Water for Mixing
Use distilled water only. Water
other than distilled water can cor-
rode and clog the aluminum radia-
tor.
Required amount of engine cool-
ant/water solution capacity (total):
1750 ml (1.8 US qt)
NOTE: This 50% mixture will
protect the cooling system from
freezing at temperatures above
–31°C (–24°F). If the motorcycle
is to be exposed to temperature
below –31°C (–24°F), this mix-
ing ratio should be increased up
to 55% (–40°C/–40°F) or 60%
(–55°C/–67°F) coolant. The mix-
ing ratio should not exceed 60%
coolant.
Engine coolant 875 ml (0.9 US qt)
Water 875 ml (0.9 US qt)