2001 Suzuki VL800K1 Volusia Intruder C50
2002 Suzuki VL800K2 Volusia Intruder C50
2003 Suzuki VL800K3 Volusia Intruder C50
2004 Suzuki VL800K4 Volusia Intruder C50
2005 Suzuki VL800K5 Volusia Intruder C50
2005 Suzuki C50TK5 Boulevard 819cc
2005 Suzuki C50K5 Boulevard 819cc
2006 Suzuki Boulevard C50T (805cc)
2006 Suzuki Boulevard C50 (805cc)

This service manual includes color wiring diagrams, 440 pages and hundreds of original photos and illustrations.

The chapter breakdown of this service manual is as follows:

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION
Manual organization/Warnings, cautions and notes/Safety/Serial numbers/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

CHAPTER TWO/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

CHAPTER THREE/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 CHAPTER FOUR/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

CHAPTER FIVE/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

CHAPTER SIX/CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cable/Clutch cover/Clutch/Clutch release mechanism/External shift mechanism/Specifications

CHAPTER SEVEN/TRANSMISSION AND INTERNAL SHIFT MECHANISM
Internal shift mechanism/Transmission/Specifications

CHAPTER EIGHT/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

CHAPTER NINE/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

CHAPTER TEN/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

CHAPTER ELEVEN/COOLING SYSTEM
Cooling system/Coolant reservoir/Radiator/Cooling fan/Thermostat/Water pump/Cooling fan switch/Engine coolant temperature (ECT) switch/Specifications

CHAPTER TWELVE/WHEELS AND TIRES
Front wheel/Rear wheel/Front wheel hub/Rear wheel hub/Wheel service/Tires/Wheel balance/Specifications

CHAPTER THIRTEEN/FRONT SUSPENSION AND STEERING
Balancer weights/Handlebar/Handlebar left hand grip replacement/Steering stem and head/Steering head bearing races/Front fork/Specifications

CHAPTER FOURTEEN/REAR SUSPENSION AND FINAL DRIVE
Shock absorber/Final drive and driveshaft/Swing arm/Shock linkage/Bearing replacement/Specifications

CHAPTER FIFTEEN/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

CHAPTER SIXTEEN/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