2007 Suzuki VL800 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: VL800 Volusia Year: 2007 Codes Vin Prefix: JS1 👋 Introduction Market Position Vehicle Segment: Cruiser Motorcycle, known for its V-twin engine and comfortable...

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类型: Motorcycle

斯库: 604050

标签: 2007 Boulevard Models Motorcycle Motorcycles Suzuki VL800

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

VL800 Volusia

Year:

Codes

Vin Prefix:

👋 Introduction

Market Position

Vehicle Segment:

Cruiser Motorcycle, known for its V-twin engine and comfortable riding posture.

Competitive Analysis

Key Competitors 2007:

Honda Shadow VT750, Yamaha V-Star 650, Kawasaki Vulcan 500 LTD.

Key Features

Distinctive Features:

Shaft drive, liquid-cooled V-twin engine, comfortable seating, classic styling.

Manual Usefulness

Target Audience:

DIY motorcycle enthusiasts, independent repair shops, and owners seeking to understand their Suzuki VL800's maintenance and repair needs.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Fuel System, Ignition System, Drivetrain, Transmission, Clutch, Chassis, Suspension, Brakes, Electrical System, Wiring Diagrams, Bodywork, Maintenance, Troubleshooting, Specifications

Page Count

Page Count:

Approximately 400-500 pages (typical for this model and year)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from routine maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic parameters.

📊 Manual Specifications

File Format

Digital Format:

Searchable PDF with high-resolution diagrams and images.

Print Quality

Diagram Clarity:

High-resolution, clear diagrams and exploded views for accurate component identification and assembly.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

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

Compression Ratio:

9.2:1

Carburetion:

Digital Fuel Injection (DFI)

Performance

Horsepower Approx:

Approx. 50 HP @ 6,500 RPM (manufacturer data varies)

Torque Approx:

Approx. 50 lb-ft @ 4,000 RPM (manufacturer data varies)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle bodies

Fuel Type:

Unleaded gasoline, minimum 87 octane

Lubrication

Oil Type:

SAE 10W-40 API SG or SH motorcycle oil

Oil Capacity:

3.4 US qt (3.2 L) with filter change

Cooling System

Coolant Type:

Ethylene glycol based antifreeze, 50/50 mix with distilled water

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Final Drive:

Shaft drive

Features

Clutch Type:

Wet, multi-plate

Fluid Specifications

Transmission Oil Type:

SAE 80W-90 API GL-4 hypoid gear oil

Transmission Oil Capacity:

1.8 US qt (1.7 L)

📐 Dimensions

Exterior

Overall Length:

9.46 ft (2,885 mm)

Overall Width:

3.05 ft (930 mm)

Overall Height:

3.74 ft (1,140 mm)

Wheelbase:

5.07 ft (1,545 mm)

Ground Clearance:

0.51 ft (155 mm)

Weights

Dry Weight:

454 lbs (206 kg)

Curb Weight:

474 lbs (215 kg)

Gvwr:

815 lbs (370 kg)

Cargo

Fuel Tank Capacity:

3.4 US gal (13.0 L)

🛡️ Safety Features

Ratings

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.

Active Features

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.

Passive Features

Frame Construction:

Steel cradle frame providing rigidity and rider protection.

💡 Technology Features

Infotainment

Infotainment System:

Basic; typically does not include integrated infotainment systems. Focus is on core motorcycle operation.

Driver Assistance

Rider Aids:

None (e.g., no ABS, traction control on base models).

Connectivity

Connectivity Features:

None.

Lighting Technology

Headlight Type:

Halogen

🔧 Maintenance

Service Intervals

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).

Fluid Specifications

Engine Oil Capacity Change:

3.2 L (3.4 US qt)

Engine Oil Filter Part Number:

Commonly 16510-01400 or equivalent (verify with manual)

Brake Fluid Type:

DOT 4

Cooling System Capacity:

2.0 L (2.1 US qt)

Known Issues

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.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Division:

Suzuki Motor Corporation has a long history in motorcycle manufacturing, known for innovation and performance across various segments.

Model Evolution

Vl800 Development:

The VL800 Volusia was introduced as a cruiser designed to compete in the mid-size segment, evolving from earlier Suzuki cruiser designs.

Production

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.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The VL800/Boulevard C50 is generally recognized as a reliable and comfortable cruiser motorcycle, well-suited for long-distance riding and general cruising.

Ratings

Owner Satisfaction:

Generally positive owner satisfaction due to its reliability and value for money in its class.