Suzuki VL800 2001 2002 2003 2004 2005 Factory Service Repair Manual

Normaler Preis: $16.99
Verkaufspreis: $16.99
Normaler Preis
Grundpreis: pro

15 people are viewing this right now

Typ: Motorcycle

Anbieter:

Art.-Nr: 136950

Stichworte: 2001 2002 2003 2004 2005 Boulevard Models Motorcycle Motorcycles Suzuki VL800

Produktvarianten

Beschreibung

This manual covers the VL800 Volusia, Intruder C50, and Boulevard C50 models produced between 2001 and 2005. These mid-size cruiser motorcycles are known for their comfortable riding position, classic styling with ample chrome, and reliable 805cc V-twin engines featuring shaft drive for low maintenance. The Volusia/Intruder/Boulevard series offers a balance of performance and accessibility, making it a popular choice for riders seeking a stylish and dependable cruiser for both touring and everyday use, competing effectively with other models in its segment. This comprehensive factory service repair manual provides detailed information necessary for the maintenance, repair, and troubleshooting of your cruiser. It covers all essential systems, including engine mechanicals, fuel, lubrication, shaft drive, chassis components, and the electrical system. The manual includes step-by-step repair procedures, diagnostic guides, technical specifications, torque values, and recommended maintenance schedules. This resource is invaluable for owners and technicians aiming to ensure the longevity, optimal performance, and safe operation of their VL800 Volusia, Intruder C50, or Boulevard C50.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VL800 Volusia / Intruder C50 / Boulevard C50

Common Name:

Volusia / Intruder C50 / Boulevard C50

Engine Type:

V-Twin Cruiser

Product Type:

Factory Service Repair Manual

Product Format:

PDF Download

Codes

Model Codes Covered:

VL800K1, VL800K2, VL800K3, VL800K4, VL800T K5, VL800K5, C50TK5, C50K5

👋 Introduction

Market Position

Segment:

Mid-size cruiser motorcycle

Target Audience:

Riders seeking a comfortable, stylish, and reliable cruiser for touring and everyday riding

Competitive Analysis

Key Competitors:

Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series

Selling Points:

Shaft drive for low maintenance, comfortable riding position, accessible price point, reliable V-twin engine

Key Features

Engine Configuration:

Air-cooled, 45-degree V-twin

Drivetrain:

Shaft drive

Styling:

Classic cruiser styling with ample chrome, forward-mounted footpegs, and swept-back handlebars

Manual Value Proposition:

Enables cost-effective maintenance and repairs, enhances understanding of vehicle systems, supports long-term ownership

📋 Manual Details

Coverage Areas

Years Covered:

2001, 2002, 2003, 2004, 2005

Trim Levels Covered:

Volusia, Intruder C50, Boulevard C50, Boulevard C50T

Page Count

Estimated Page Count:

Likely 400-600 pages (typical for factory service manuals of this era)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

File Format:

Printability:

Compatibility

Operating Systems:

WINDOWS and MAC

Requirements

Required Software:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, top-end rebuild, bottom-end inspection, piston, rings, cylinder, camshaft, valve train, crankshaft, connecting rods

Fuel System:

Carburetor specifications, cleaning, adjustment, fuel pump, fuel lines, fuel filter replacement

Lubrication System:

Oil pump, oil passages, oil filter, oil capacity and specifications

Cooling System:

Radiator, fan, thermostat, coolant specifications and capacity (Note: VL800 is air-cooled, so this likely pertains to oil cooling aspects if applicable or is a general section)

Shaft Drive:

Rear drive unit maintenance, lubrication, seals, and disassembly/assembly

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system, bearings, wheels, brakes (front and rear), brake fluid specifications

Electrical System:

Ignition system, starting system, charging system (alternator, battery), lighting (headlight, taillight, indicators), horn, wiring diagrams, fuses, relays, sensors

Emission Control:

Emissions-related components, evaporative emissions control (if applicable), troubleshooting of emission-related faults

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable, though shaft drive here), brake adjustments, clutch adjustments

Troubleshooting:

Diagnostic procedures for common issues, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation

Specifications Data:

Torque values, clearances, fluid capacities, electrical specifications, performance data

Periodic Maintenance Schedule:

Recommended service intervals for various maintenance tasks

Technical Depth

Depth Of Coverage:

Comprehensive factory-level detail, suitable for dealership technicians and experienced DIY mechanics

Diagnostic Capabilities:

Includes diagnostic charts and troubleshooting trees for electrical and mechanical issues

Rebuild Instructions:

Detailed instructions for complete engine and component rebuilds

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, allowing for quick keyword lookups

Print Quality

Print Recommendation:

High-quality printing recommended for clarity of diagrams and text

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

805 cc (approx. 49.1 cubic inches)

Bore X Stroke:

97.0 mm x 100.0 mm

Compression Ratio:

9.3:1 (Typical for this era)

Valve Train:

SOHC, 4 valves per cylinder (3 valves intake, 1 exhaust typically)

Performance

Horsepower:

Approx. 50-55 HP (at crankshaft)

Torque:

Approx. 50-55 lb-ft (at crankshaft)

Fuel System

Carburetion:

Twin Keihin carburetors (e.g., CVK36)

Fuel Capacity:

Approx. 15.5 Liters (4.1 US gallons)

Cooling System

Cooling Method:

Air-cooled, with an oil cooler

Ignition

Ignition System:

Electronic ignition (CDI)

Exhaust

Exhaust System:

Dual exhaust pipes

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet multi-plate

Final Drive:

Shaft drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2350 mm (92.5 in)

Overall Width:

Approx. 945 mm (37.2 in)

Overall Height:

Approx. 1110 mm (43.7 in)

Wheelbase:

Approx. 1655 mm (65.2 in)

Ground Clearance:

Approx. 140 mm (5.5 in)

Weights

Dry Weight:

Approx. 221 kg (487 lbs)

Curb Weight:

Approx. 232 kg (511 lbs)

Gvwr:

Not typically specified in this format for motorcycles, but implied by component ratings.

Interior

Seating Capacity:

1-2 (Rider and Passenger)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A for motorcycles in the same manner as cars.

Active Features

Braking System:

Front: Hydraulic disc; Rear: Drum brake (early models) or Hydraulic disc (later variations/upgrades)

Lighting:

Halogen headlight, LED taillight/brake light, amber turn signals

Passive Features

Frame Construction:

Steel double-cradle frame

💡 Technology Features

Infotainment

Audio System:

N/A (Typically no factory-installed audio)

Instrumentation:

Analog speedometer, tachometer (on some models/trims), fuel gauge, indicator lights

Driver Assistance

N/A (Anti-lock Braking System was not standard or commonly available on this model during these years)

Connectivity

Bluetooth:

Lighting Tech

Headlight Type:

Halogen

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 miles or 6 months (refer to manual for exact specification)

Spark Plug Replacement:

Every 12,000-18,000 miles

Air Filter Maintenance:

Clean/replace every 7,500-10,000 miles or as needed based on riding conditions

Shaft Drive Oil Change:

Every 12,000-18,000 miles or as specified

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH (or higher) motorcycle-specific oil

Engine Oil Capacity:

Approx. 2.7 Liters (with filter change)

Brake Fluid Type:

DOT 4

Shaft Drive Oil Type:

Hypoid gear oil (e.g., SAE 80W-90 GL-5)

Coolant Type:

N/A (Air-cooled with oil cooler)

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, wheel bearings

Potential Electrical Gremlins:

Corrosion on connectors, regulator/rectifier issues (less common on this model compared to some older bikes)

Carburetor Tuning:

Can require periodic adjustment or cleaning due to typical cruiser usage patterns (short trips)

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Suzuki Motor Corporation, Japan

Model Evolution

Predecessor:

Suzuki VS800 Intruder

Name Changes:

Introduced as the VL800 Volusia, later renamed Intruder C50 and then Boulevard C50 for the North American market to align with Suzuki's Boulevard branding for cruisers.

Production

Production Years Covered:

2001-2005

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

Common Owner Feedback:

Praised for its comfortable ride, reliability, and value for money in the cruiser segment.

Ratings

Motorcycle Reviews:

Generally received positive reviews for its accessible nature and classic styling.

Certifications

Emissions Standards:

Meets relevant emissions standards for the model years and regions of sale.