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
Model Codes Covered:
VL800K1, VL800K2, VL800K3, VL800K4, VL800T K5, VL800K5, C50TK5, C50K5
Segment:
Mid-size cruiser motorcycle
Target Audience:
Riders seeking a comfortable, stylish, and reliable cruiser for touring and everyday riding
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
Engine Configuration:
Air-cooled, 45-degree V-twin
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
Years Covered:
2001, 2002, 2003, 2004, 2005
Trim Levels Covered:
Volusia, Intruder C50, Boulevard C50, Boulevard C50T
Estimated Page Count:
Likely 400-600 pages (typical for factory service manuals of this era)
Manual Type:
Factory Service Repair Manual
Operating Systems:
WINDOWS and MAC
Required Software:
Adobe PDF Reader
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
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
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
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)
Horsepower:
Approx. 50-55 HP (at crankshaft)
Torque:
Approx. 50-55 lb-ft (at crankshaft)
Carburetion:
Twin Keihin carburetors (e.g., CVK36)
Fuel Capacity:
Approx. 15.5 Liters (4.1 US gallons)
Cooling Method:
Air-cooled, with an oil cooler
Ignition System:
Electronic ignition (CDI)
Exhaust System:
Dual exhaust pipes
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
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)
Shaft Drive Oil Type:
Hypoid gear oil (e.g., SAE 80W-90 GL-5)
Coolant Type:
N/A (Air-cooled with oil cooler)
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)
