2002 Suzuki Intruder problems, complaints & recalls
Most-reported problem areas: Fuel System, Gasoline:storage:tank Assembly (4) · Power Train:manual Transmission (2) · Power Train:clutch Assembly (2)
🧭 Reliability snapshot
Compared against other Suzuki Intruder model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (1)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Fuel System, Other 2004-09-15 · 25 · Service Bulletin/Repair Instructions
fuel system evaporative emissions canister replacement. suzuki. 2001-2004 volusia and 1999 - 2004 intruder. *tt
What owners report
2014-04-15 · Fuel/Propulsion System · 11,900 mi“stator and rectifyer went on ny 2002 suzuki 1500 intruder. i am reading that this is a huge problem for this model. it caused me to lose power while driving. this is in need of a recall. *tt…”
2006-04-02 · Fuel System, Other:storage:tank Assembly“i am the recipient of a gas tank recall on a suzuki 1500 intruder motorcycle and have received virtually no assistance with regards to making the vehicles safe in a reasonable period of time - i have been without this mode of transportation since march 11 due to this manufacturing defect and there is still no eta from suzuki on when the motorcycle …”
2005-09-19 · Service Brakes, Hydraulic:foundation Components:disc:pads · 9,700 mi“dt: the consumer states that there is something wrong with the rear brakes. the piston is pressing the pad against the caliper and will not release. the pads are wearing out real fast. the dealer/ manufacturer have been notified. there has been no response. *ak the consumer stated there has been a problem with the caliper since the motorcycle was…”
2004-11-17 · Fuel System, Gasoline:storage:tank Assembly · 10,000 mi“fuel tank developed a hair line crack above the front right mounting tab. this began leaking gas vapors which have grown worse over time.*ak…”
2004-11-15 · Fuel System, Gasoline:storage:tank Assembly · 22,600 mi“i kept smelling gas fumes and found a hair-line crack in the top of the gas tank at the right front mounting tab with fuel seepage apparent. *ak …”
2004-11-14 · Fuel System, Gasoline:storage:tank Assembly · 6,000 mi“bought my suzuki 1500 intruder motorcycle new from aj foyt suzuki/kawasaki in houston ,texas, at 6,000 miles the fuel tank weld cracked and started leaking fuel!!,, there are dozens of others in my suzuki forum club with the same problem. *jb…”
2004-05-16 · Power Train:manual Transmission · 500 mi“would pop out of 4th gear while accelerating going up hill or putting any load on it. called mt local dealer and took it right in. they are in the process of replacing the cam stop plate and pins. should have it back next week. *ak…”
2004-03-22 · Power Train:manual Transmission · 1,000 mi“transmission will not downshift to first gear without lifting up on the shifter to ratchet it into position. it was taken to dealer for repair under warr.but problem was not fixed at all.*ak…”
2004-01-28 · Fuel System, Gasoline:storage:tank Assembly · 15,000 mi“2002 suzuki intruder vl1500 - the fuel tank has developed a stress fracture or crack on the right hand side of the tank. specifically it is located on the right hand mounting flange starting in the vicinity of the right front mounting bolt. the crack extends forward approximately 2" and "looks" like a fine scratch in the black paint. on further ins…”
2003-12-04 · Power Train:automatic Transmission:lever And Linkage:floor Shift“while shifting gears, the transmission would down shift on its own. the driver took the motorcycle to the dealer for analysis. the mechanic noticed that the gear shaft needed replacing. *ph…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.