2005 Suzuki VL800 Service Repair Manual

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This manual covers the Suzuki VL800 Volusia, Intruder C50, and Boulevard C50 models from 2001 to 2005, built upon the VL800 platform. These motorcycles are known for their reliable air-cooled...

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Taper: Motorcycle

Distributeur:

UGS: 142950

Mots clés: 2005 Boulevard Models Motorcycle Motorcycles Suzuki VL800

Variantes de produits

Description

This manual covers the Suzuki VL800 Volusia, Intruder C50, and Boulevard C50 models from 2001 to 2005, built upon the VL800 platform. These motorcycles are known for their reliable air-cooled V-twin engines, comfortable cruiser styling, and shaft drive, making them a popular choice for touring and everyday riding. Their engineering emphasizes a balance of classic aesthetics and practical performance, originating from robust manufacturing heritage. This comprehensive factory service repair manual provides detailed instructions for the repair, maintenance, and rebuilding of your Suzuki motorcycle. It covers all essential systems, including the engine, fuel and lubrication, cooling, transmission, chassis, electrical systems, brakes, and bodywork. With step-by-step procedures, abundant illustrations, and critical technical specifications, this manual is an indispensable resource for owners and technicians seeking to maintain their vehicle's optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VL800 Volusia / Intruder C50 / Boulevard C50

Model Years Covered:

2001, 2002, 2003, 2004, 2005

Platform Codename:

VL800 (Volusia generation)

Variant Identifiers:

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

👋 Introduction

Market Position

Target Audience:

Owner-operators, independent repair shops, enthusiast mechanics

Competitive Analysis

Value Proposition:

Provides factory-level repair information at a fraction of the cost of dealership service, enabling cost-effective maintenance and repairs.

Key Features

Comprehensiveness:

Covers all aspects of mechanical and electrical systems for the specified model years and variants.

User Friendliness:

Organized with clear headings, step-by-step instructions, and illustrative diagrams for ease of use.

📋 Manual Details

Coverage Areas

Primary Coverage:

Factory Service Repair Manual

Detailed Coverage:

Repair, maintenance, rebuilding, refurbishment, restoration, troubleshooting

Page Count

Estimated Page Count:

Varies by specific edition, typically 300-500 pages

Manual Type

Type:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

File Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, and repair of the engine (V-twin)

Fuel And Lubrication:

Fuel system components (carburetor, fuel pump, lines), lubrication system (oil pump, filter, passages), oil change procedures, oil specifications

Cooling System:

Liquid cooling system components (radiator, hoses, fan, thermostat), coolant specifications, bleeding procedures

Transmission And Drivetrain:

Gearbox, clutch, shaft drive system (including final drive and universal joint)

Chassis And Suspension:

Frame, front fork (telescopic), rear suspension (swingarm, shock absorbers), steering system

Electrical System:

Ignition system, lighting, starting system, charging system, battery, wiring diagrams, component testing

Emission Control:

Emission control systems and related adjustments

Braking System:

Front and rear brake mechanisms (disc/drum), hydraulic system, bleeding, pad/shoe replacement

Wheels And Tires:

Wheel specifications, tire pressure, mounting, balancing

Bodywork And Fittings:

Body panels, seat, handlebars, fuel tank, fenders, decorative elements

Procedures Included

Maintenance:

Periodic maintenance checks, fluid changes, filter replacements, lubrication, cable adjustments

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault identification

Repair And Rebuild:

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

Wiring Schematics:

Detailed electrical wiring diagrams for accurate diagnosis and repair

Torque Specifications:

Critical torque values for fasteners to ensure proper assembly and safety

Technical Depth

Depth:

Factory-level detail, suitable for both novice DIY enthusiasts and experienced professional mechanics

Illustrations

Diagrams And Illustrations:

Abundant exploded views, line drawings, and photographic illustrations to guide procedures

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Printable:

Compatibility

Operating Systems:

Windows and MAC compatible

Requirements

Software Requirement:

Adobe PDF Reader

Delivery

Delivery Method:

Instant Digital Download (no shipping or waiting)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, SOHC, 8-valve, 4-stroke V-twin

Engine Displacement:

805 cc (804 cm³ / 49.1 cu.in.) - denoted as 819cc for Boulevard models due to bore/stroke adjustment for C50 variants.

Performance

Bore X Stroke:

70.0 mm x 84.0 mm (VL800); 72.0 mm x 84.0 mm (C50 variants)

Compression Ratio:

9.4:1

Horsepower:

Approx. 50 HP @ 6,000 RPM (varies slightly by model year and specific variant)

Torque:

Approx. 50 lb-ft @ 3,200 RPM (varies slightly by model year and specific variant)

Fuel System

Carburetion:

Two 36mm Mikuni carburetors (BST36) for VL800 models; Fuel injection (EFI) for C50 models (starting in 2005 for some variants)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Lubrication System

Oil Type:

SAE 10W-40 API SG or higher, JASO MA

Oil Capacity:

Approx. 3.2 Liters (3.4 US qt) with filter change

Cooling System

Coolant Type:

Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze) with distilled water (50:50 mix)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Features

Clutch:

Wet multi-plate

Final Drive:

Shaft drive

Fluid Specifications

Final Drive Oil Type:

Gear oil GL-5 75W-90

📐 Dimensions

Exterior

Overall Length:

Approx. 2335 mm (91.9 in)

Overall Width:

Approx. 975 mm (38.4 in)

Overall Height:

Approx. 1100 mm (43.3 in)

Wheelbase:

Approx. 1640 mm (64.6 in)

Weights

Dry Weight:

Approx. 222 kg (489 lbs)

Curb Weight:

Approx. 233 kg (514 lbs)

🛡️ Safety Features

Ratings

Safety Certification:

Meets applicable federal motor vehicle safety standards (FMVSS) for motorcycles.

Active Features

Braking System Type:

Front: Hydraulic disc brake; Rear: Drum brake (some later models may have disc options)

Passive Features

Lighting:

Halogen headlight, LED taillight, turn signals

💡 Technology Features

Infotainment

Features:

Primarily mechanical and functional focus; lacks modern infotainment systems. Basic instrumentation (speedometer, tachometer, fuel gauge, indicator lights).

Driver Assistance

Features:

No advanced driver-assistance systems (ADAS) or electronic rider aids beyond standard safety features.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km (3,700 mi) or 6 months

Spark Plug Inspection:

Every 12,000 km (7,500 mi)

Air Filter Cleaning:

Every 6,000 km (3,700 mi)

Drive Shaft Oil Change:

Every 12,000 km (7,500 mi) or 12 months

Coolant Replacement:

Every 24,000 km (15,000 mi) or 24 months

Fluid Specifications

Brake Fluid:

DOT 4

Fork Oil Type:

SAE 10W

Known Issues

Common Wear Items:

Clutch plates, brake pads/shoes, wheel bearings, fork seals, exhaust system (corrosion)

Carburetor Tuning:

Carburetor synchronization and cleaning can be necessary for optimal performance on older models.

Electrical Connections:

Corrosion or looseness in electrical connectors can sometimes lead to intermittent issues.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Model Evolution

Predecessor:

Suzuki VS800 Intruder (V-twin engine platform basis)

Name Changes:

Introduced as the VL800 Volusia, rebranded as Intruder C50, and later as Boulevard C50, reflecting Suzuki's marketing strategy.

Production

Introduction Year:

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A (As a service manual, it doesn't receive awards. The vehicle itself was well-regarded for its styling and value.)