2001-2011 Suzuki Volusia Boulevard C50 Clymer Motorcycle Repair Manual

Description

This 2001-2011 Suzuki Volusia Boulevard C50 Clymer Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following motorcycles:

2011 Suzuki VL800T Boulevard C50T
2011 Suzuki VL800C Boulevard C50C
2011 Suzuki VL800 Boulevard C50
2010 Suzuki VL800T Boulevard C50T
2010 Suzuki VL800C Boulevard C50C
2010 Suzuki VL800 Boulevard C50
2009 Suzuki VL800T Boulevard C50T
2009 Suzuki VL800C Boulevard C50C
2009 Suzuki VL800 Boulevard C50
2008 Suzuki VL800TK8 Boulevard C50
2008 Suzuki VL800K8 Boulevard C50
2008 Suzuki VL800CK8 Boulevard C50
2007 Suzuki VL800T K7 Boulevard C50
2007 Suzuki VL800K7 Boulevard C50
2007 Suzuki VL800C K7 Boulevard C50
2006 Suzuki VL800TK6 C50
2006 Suzuki Boulevard C50T (805cc)
2006 Suzuki Boulevard C50 (805cc)
2005 Suzuki VL800K5 Volusia Intruder C50
2005 Suzuki C50TK5 Boulevard 819cc
2005 Suzuki C50K5 Boulevard 819cc
2004 Suzuki VL800K4 Volusia Intruder C50
2003 Suzuki VL800K3 Volusia Intruder C50
2002 Suzuki VL800K2 Volusia Intruder C50
2001 Suzuki VL800K1 Volusia Intruder C50

This service manual includes color wiring diagrams, 428 pages and hundreds of original photos and illustrations.

The chapter breakdown of this service manual is as follows:

QUICK REFERENCE DATA
Suzuki Volusia Boulevard C50 GENERAL INFORMATION

Manual organization, Warnings, cautions and notes, Safety, Serial numbers, Fasteners, Shop supplies, Tools, Measuring tools, Electrical system fundamentals, Service methods, Storage, Specifications
Suzuki Volusia Boulevard C50 TROUBLESHOOTING

Starting the engine, Engine will not start, Engine performance, Engine noises, Engine lubrication, Oil pressure test, Leakdown test, Clutch, Gearshift linkage, Transmission, Fuel system (carbureted models), Electronic diagnostic system, Electrical testing, Lighting system, Charging system, Ignition system, Starting system, Suspension and steering, Brake system
Suzuki Volusia Boulevard C50 LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride check list, Maintenance schedule, Tires and wheels, Battery, Periodic lubrication, Periodic maintenance, Non-scheduled maintenance, Tune-up, Valve clearance, Compression test, Spark plugs, Ignition timing, Fuel system adjustment, Specifications
Suzuki Volusia Boulevard C50 ENGINE TOP END

Cylinder head cover caps, Cylinder head covers, Rocker arm assemblies, Camshafts, Cylinder head and cylinder, Cylinder head, Valves and valve components, Camshaft chain tensioner, Cylinder, Pistons and piston rings, Specifications
Suzuki Volusia Boulevard C50 ENGINE LOWER END

Engine, Oil pump, Starter clutch and gears, Primary drive gear, Camshaft drive chains and drive sprockets, Secondary gear assembly, Crankcase, Crankshaft and connecting rods, Break-in, Specifications
Suzuki Volusia Boulevard C50 CLUTCH AND EXTERNAL SHIFT MECHANISM

Clutch cable, Clutch cover, Clutch, Clutch release mechanism, External shift mechanism, Specifications
Suzuki Volusia Boulevard C50, TRANSMISSION AND INTERNAL SHIFT MECHANISM

Internal shift mechanism, Transmission, Specifications
Suzuki Volusia Boulevard C50, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (2001-2004 MODELS)

Carburetor, Pilot screw, Carburetor float height, Throttle position (TP) sensor, Carburetor heater (U.K. models), Throttle cable, Starter (choke) cable, Air box, Fuel tank, Fuel valve, Fuel pump, PAIR (air supply) system, Crankcase breather system, Evaporative emission control system (California models), Exhaust system, Specifications
Suzuki Volusia Boulevard C50, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (2005-ON MODELS)

Electronic fuel injection (EFI), Fuel delivery system tests, Fuel pump, Fuel pump relay, Fuel pressure regulator, Throttle cable, Air box, Throttle body, Fuel injectors, Crankshaft position (CKP) sensor, Throttle position (TP) sensor, Secondary throttle position (STP) sensor, Secondary throttle valve actuator (STVA), Fast idle speed, Intake air pressure (IAP) sensors, Engine coolant temperature (ECT) sensor, Intake air temperature (IAT) sensor, Heated oxygen (HO2) sensor, Tip-over (TO) sensor, Fuel tank, PAIR (air supply) system, Evaporative emission control system (California models), Exhaust system, Specifications
Suzuki Volusia Boulevard C50 ELECTRICAL SYSTEM

Peak voltage and resistance testing, Electrical component replacement, Electrical connectors, Charging system, Voltage regulator, rectifier, Alternator, Electronic ignition system, Igniter (2001-2004 models), Electronic control module (ECM) (2005-on models), Starter system, Starter relay, Lighting system, Switches, Relay assembly, Speedometer, Horn, Cooling system, Fuses, Wiring diagrams, Specifications
Suzuki Volusia Boulevard C50 COOLING SYSTEM

Cooling system, Coolant reservoir, Radiator, Cooling fan, Thermostat, Water pump, Cooling fan switch, Engine coolant temperature (ECT) switch, Specifications
Suzuki Volusia Boulevard C50 WHEELS AND TIRES

Front wheel, Rear wheel, Front wheel hub, Rear wheel hub, Wheel service, Tires, Wheel balance, Specifications
Suzuki Volusia Boulevard C50 FRONT SUSPENSION AND STEERING

Balancer weights, Handlebar, Handlebar left hand grip replacement, Steering stem and head, Steering head bearing races, Front fork, Specifications
Suzuki Volusia Boulevard C50 REAR SUSPENSION AND FINAL DRIVE

Shock absorber, Final drive and driveshaft, Swing arm, Shock linkage, Bearing replacement, Specifications
Suzuki Volusia Boulevard C50 BRAKES

Brake fluid selection, Brake service, Front brake pads, Front brake caliper, Front brake master cylinder, Front brake hose, Front brake disc, Brake bleeding, Rear drum brake, Rear brake pedal, Rear brake pivot lever, Specifications
Suzuki Volusia Boulevard C50 BODY AND FRAME

Seats, Frame side covers, Frame head side covers, Toolbox, Sidestand, Front fender, Rear fender, Left footpeg, footrest, Right footpeg, footrest, Specifications

INDEX

Suzuki Volusia Boulevard C50 WIRING DIAGRAMS