Vehicle Segment:
Cruiser Motorcycle, known for its V-twin engine and comfortable riding posture.
Key Competitors 2007:
Honda Shadow VT750, Yamaha V-Star 650, Kawasaki Vulcan 500 LTD.
Distinctive Features:
Shaft drive, liquid-cooled V-twin engine, comfortable seating, classic styling.
Target Audience:
DIY motorcycle enthusiasts, independent repair shops, and owners seeking to understand their Suzuki VL800's maintenance and repair needs.
Systems Covered:
Engine, Fuel System, Ignition System, Drivetrain, Transmission, Clutch, Chassis, Suspension, Brakes, Electrical System, Wiring Diagrams, Bodywork, Maintenance, Troubleshooting, Specifications
Page Count:
Approximately 400-500 pages (typical for this model and year)
Manual Type:
Service and Repair Manual
Engine Mechanical:
Detailed procedures for disassembly, inspection, repair, and reassembly of the engine, including cylinder head, pistons, crankshaft, connecting rods, camshafts, valves, and oil pump.
Fuel System:
Coverage of fuel tank, fuel pump, fuel injectors, throttle body, fuel pressure regulator, and associated lines and components.
Ignition System:
Information on spark plugs, ignition coils, ignition control module, and troubleshooting ignition-related faults.
Drivetrain Transmission:
Comprehensive repair instructions for the transmission, including clutch assembly, gears, shift mechanism, and transmission fluid service.
Chassis Frame:
Details on frame inspection, repair, and component mounting points.
Suspension Steering:
Repair and adjustment procedures for front and rear suspension components, forks, shock absorbers, and steering system.
Braking System:
Service and repair of front and rear brakes, including brake pads, rotors, calipers, master cylinder, and brake lines.
Electrical System:
Detailed wiring diagrams, troubleshooting guides for electrical components, lighting, battery, starter motor, and charging system.
Bodywork Fittings:
Information on body panel removal and installation, seat, fuel tank, fenders, and accessories.
Preventive Maintenance:
Scheduled maintenance tasks, lubrication points, filter replacements, and general upkeep recommendations.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting charts.
Engine Overhaul:
Step-by-step instructions for complete engine rebuilds and component replacement.
Transmission Repair:
Detailed guidance on clutch replacement, gear inspection, and transmission disassembly/reassembly.
Electrical Diagnostics:
Guidance on using multimeters, diagnosing electrical faults, and repairing wiring harness issues.
Suspension Fork Service:
Instructions for fork seal replacement, oil changes, and suspension adjustments.
Brake System Maintenance:
Procedures for brake pad replacement, bleeding the brake system, and caliper service.
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic parameters.
Engine Type:
805cc (49.1 cu in) V-twin, 4-stroke, SOHC, 8-valve, liquid-cooled
Bore X Stroke:
83.0 mm x 74.4 mm
Carburetion:
Digital Fuel Injection (DFI)
Horsepower Approx:
Approx. 50 HP @ 6,500 RPM (manufacturer data varies)
Torque Approx:
Approx. 50 lb-ft @ 4,000 RPM (manufacturer data varies)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
SAE 10W-40 API SG or SH motorcycle oil
Oil Capacity:
3.4 US qt (3.2 L) with filter change
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water
Safety Features Overview:
As a motorcycle, safety relies on rider skill and mechanical integrity. The manual focuses on maintaining braking, steering, and suspension systems for optimal safety.
Braking System Type:
Dual hydraulic disc front, Drum rear (some markets may have rear disc)
Lighting System:
Halogen headlamp, LED tail light, incandescent turn signals.
Frame Construction:
Steel cradle frame providing rigidity and rider protection.
First Service Km:
1,000 km (oil change, check fasteners, adjust chain if applicable - though this has shaft drive)
Subsequent Service Km:
Every 4,000 km or 6 months, whichever comes first (engine oil change, filter inspection/replacement, spark plug check, brake fluid check, etc.)
Major Service Intervals:
Refer to manual for specific mileage intervals for valve clearance checks, coolant changes, and brake fluid replacement (typically every 2 years or per mileage).
Engine Oil Capacity Change:
3.2 L (3.4 US qt)
Engine Oil Filter Part Number:
Commonly 16510-01400 or equivalent (verify with manual)
Cooling System Capacity:
2.0 L (2.1 US qt)
Common Wear Items:
Tires, brake pads, clutch plates (depending on usage), spark plugs.
Potential Maintenance Concerns:
Regular inspection of the shaft drive boot and universal joint is recommended. Proper coolant maintenance is crucial for the liquid-cooled engine.
Suzuki Motorcycle Division:
Suzuki Motor Corporation has a long history in motorcycle manufacturing, known for innovation and performance across various segments.
Vl800 Development:
The VL800 Volusia was introduced as a cruiser designed to compete in the mid-size segment, evolving from earlier Suzuki cruiser designs.
Manufacturing Location:
Primarily manufactured in Japan and/or under license in other countries.
Production Years Vl800:
2001-2004 (as Volusia), rebadged/updated as Boulevard C50 from 2005 onwards. This manual specifically covers the 2007 model, which is the Boulevard C50.
