AI Damage2002 Suzuki Intruder: common problems
Owners of the 2002 Suzuki Intruder filed 14 complaints with NHTSA, most often about fuel system and powertrain. Details by component below, with sources.
Key figures
- Owner complaints
- 14
What fails most often
- 1 Fuel system 36% of all complaints
- 2 Powertrain 36% of all complaints
- 3 Electrical system 7% of all complaints
- 4 Engine and cooling 7% of all complaints
- 5 Exterior lighting 7% of all complaints
- 6 Fuel/propulsion system 7% of all complaints
- 7 Service brakes 7% of all complaints
- Fuel system: 5 complaints (36% of all).
- Powertrain: 5 complaints (36% of all).
- Electrical system: 1 complaints (7% of all).
- Engine and cooling: 1 complaints (7% of all).
- Exterior lighting: 1 complaints (7% of all).
Symptoms owners describe
How many of the 14 NHTSA complaints mention each symptom (automatic count from complaint text; one complaint can mention several).
Components owners complain about
| Component | Owner complaints | involving a crash | Technical service bulletins (TSB) |
|---|---|---|---|
| Fuel system | 5 | 0 | 0 |
| Powertrain | 5 | 0 | 0 |
| Electrical system | 1 | 0 | 0 |
| Engine and cooling | 1 | 0 | 0 |
| Exterior lighting | 1 | 0 | 0 |
| Fuel/propulsion system | 1 | 0 | 0 |
| Service brakes | 1 | 0 | 0 |
What owners report
Short excerpts of NHTSA complaints in the original wording. These are owner statements not verified by NHTSA; personal data removed.
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.
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…
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.
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.
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.
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.
On further inspection the crack will open or flex and fuel leaks through the crack by pressing downward on the top of the fuel tank. Fuel also leaks through the crack when the tank is half full or more with fuel.
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.
When owners complained
NHTSA complaints by filing year. The peak shows at what age the problems show up most.
Comparison
By complaint count this model year ranks 9,551 of 36,656 model years in the NHTSA data (top 26% most complained about).
On average one model year of the Intruder has 8 complaints (13 years in the data). This year has 14, above average.
What to check before buying
- Fuel system. Fuel smell, leaks, rough running, fuel-system codes.
- Powertrain. Shift quality under load, harsh shifts, transmission codes, CV joints.
- Electrical system. Scan all modules, test the battery and alternator, inspect connectors near the impact zone.
- Engine and cooling. Radiator and fan after a frontal hit, coolant level and condition, overheating.
Other years of this model
Questions and answers
What are the most common problems with the 2002 Suzuki Intruder?
Owner complaints to NHTSA most often mention: fuel system, powertrain, electrical system. Total complaints: 14. The most frequent symptoms in complaint texts: fuel system, fuel smell (7%), stalls while driving (7%).
How many service bulletins (TSB) were issued for the 2002 Suzuki Intruder?
NHTSA lists 0 manufacturer service bulletins for this year. A bulletin tells dealers how to diagnose or fix a known issue; it is not a recall.
Should I buy a 2002 Suzuki Intruder from a US auction?
Owner complaints describe defects, not crash damage. Before bidding, check the components listed above and review the lot photos: VinWind builds a report of visible and hidden damage by VIN.
Other 2002 models
Read also
Sources: public NHTSA data (USA): service bulletins and owner complaints; YouTube: links to videos credited to their authors. Complaints are owner statements not verified by NHTSA, and describe defects rather than crash damage. Data updated 2026-11-05.