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I have a 2003 Suzuki Intruder Volusia 800vl. The motor blew up. I am going to replace the motor myself. I need to find a web site or source that will tell me what motors will bolt in or some other way to find out if any other engines are a match? Any and all information is appreciated. Thanks Mac
 

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Easy answer: the only engine that will fit is the engine out of another Suzuki VL800 Volusia. The Volusia was sold 2001-2004, the first couple years being called the "Intruder Volusia" and the last couple years just the 'Volusia."

The other bikes carrying the "Intruder" name are radically different and use completely different engines, so they will not fit. After 2004 the VL800 was renamed the "Boulevard C50" and given fuel injections. This required different electronics, wiring harness, and fuel tank, so the engine from a 2005-2014 VL800 will NOT bolt in either.

My personal advise, based on 30 years of wrenching on motorcycles, 15 years working in the industry, and currently owning an independent repair shop: Don't do it. Just junk the bike and use the money you would have spent repairing it as a down payment on another one. Get another VL800 and you can swap over the accessories and even the fenders/ tank if you like your current color better. If you look around you can find a very nice Volusia in the $1750-2500 range. You can easily spend nearly that much on a used engine, and at least half the used engines on the market on Ebay and such are worthless junk and a waste of money. The engine is the weak point in the Volusia, so there are lots of perfectly good bikes out there with blown motors, and very few good motors in junked bikes. How do you know the replacement engine will not blow up in a year, or a month, or a week, or an hour? After all, it the bike it came from ended up in a junkyard, so what kind of life did it lead and what kind of maintenance did it get? How do you know how many miles are on the used engine? How do you know it even runs? How do you know that the transmission half of the unit is OK? Is the clutch in it OK? Are you just gonna take a seller's word for these things? Do you have the skills and tools to do a compression check when you get it, and to check for a blown head gasket, cracked heads, clogged oil pick up, or the hundred other problems that could be there? If you get a warranty, who covers shipping to send it back? For that matter, how will you get it to a trucking terminal to get it shipped back- truck freight companies do not pick up at residential homes. $2000 on a running motorcycle is a safer bet than $1500 on a used engine that has a 50-50 shot of being a waste of your money. And if you can find one, and it does turn out to be OK, and the transmission portion of the unit is also OK, and it was stored properly, and it gets shipped to your home without damage, do you have a way to unload it from the truck? Do you have all the tools to make the swap, or will you have to buy some? What will the swap really cost you once you add up the cost of the engine, shipping, consumables like oil, coolant, etc, any tools you need to buy, replacement gaskets for the valve and side covers (which you will need to remove to inspect the engine before installing), etc etc etc...plus do you really have the know how to do it? Do you have a helper to assist you in lifting the old engine out and the new one in? Have a way to dispose of the old engine?
 
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