Suzuki VL800 Volusia, Boulevard C50/C50T & VL800/C/TK9 Motorcycle Service Manual: Precision Maintenance & Troubleshooting (2001–2009)
Product Gallery
Sample pages from the Suzuki VL800 Volusia, Boulevard C50/C50T & VL800/C/TK9 Motorcycle Service Manual: Precision Maintenance & Troubleshooting (2001–2009) manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 26583 / Mary Wright
- File Size:
- 17.91 MB
- File Type:
- Language:
- English
- Pages:
- 639
- Printable:
- Yes
- Estimated Download Time:
- 0.37 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Motorcycle
- Brand:
- Suzuki
- Reviewed and Approved:
- Dec 26, 2025
Suzuki Models and Parts Covered in this Motorcycle Manual
- Suzuki VL800 (2001)
- Suzuki VL800K1 (2001)
- Suzuki VL800 Volusia (2001)
- Suzuki VL800K2 (2002)
- Suzuki VL800 Volusia (2002)
- Suzuki VL800K3 (2003)
- Suzuki VL800 Volusia (2003)
- Suzuki VL800K4 (2004)
- Suzuki VL800 Volusia (2004)
- Suzuki VL800K5 (2005)
- Suzuki Boulevard C50 (2005)
- Suzuki VL800TK5 (2005)
- Suzuki Boulevard C50T (2005)
- Suzuki VL800K6 (2006)
- Suzuki Boulevard C50 (2006)
- Suzuki VL800TK6 (2006)
- Suzuki Boulevard C50T (2006)
- Suzuki VL800K7 (2007)
- Suzuki Boulevard C50 (2007)
- Suzuki VL800TK7 (2007)
- Suzuki Boulevard C50T (2007)
- Suzuki VL800K8 (2008)
- Suzuki Boulevard C50 (2008)
- Suzuki VL800TK8 (2008)
- Suzuki Boulevard C50T (2008)
- Suzuki VL800K9 (2009)
- Suzuki Boulevard C50 (2009)
- Suzuki VL800C (2009)
- Suzuki Boulevard C50 Custom (2009)
- Suzuki VL800TK9 (2009)
- Suzuki Boulevard C50T (2009)
Complete Manual Information
2001-2009 Suzuki VL800 Volusia & Boulevard C50 Series Service Manual
Ensure your cruiser stays in showroom condition with the definitive 2001-2009 Suzuki VL800 / C50 series factory service manual. This is the exact technical resource used by authorized Suzuki dealerships, providing professional-grade maintenance and repair procedures for every iteration of this legendary 805cc V-twin platform.
This manual is tailored for the high-performance liquid-cooled 4-stroke OHC engine, covering the transition from the carbureted Volusia era to the fuel-injected Boulevard C50 generation. Whether you are performing a simple oil change or a complete engine overhaul, this guide offers the precise torque specs and step-by-step instructions required for success.
Comprehensive Model Coverage
This manual provides specialized data for all regional specifications (USA, Canada, EU, UK, Australia, and California) and includes all critical model updates:
- Suzuki VL800 / K1 / Volusia (2001)
- Suzuki VL800 K2 / Volusia (2002)
- Suzuki VL800 K3 / Volusia (2003)
- Suzuki VL800 K4 / Volusia (2004)
- Suzuki VL800 K5 / Boulevard C50 / C50T (2005)
- Suzuki VL800 / TK6 / Boulevard C50 (2006)
- Suzuki VL800 / TK7 & TK8 / Boulevard C50 (2007-2008)
- Suzuki VL800 / C / TK9 / Boulevard C50 Custom (2009)
Essential Technical Sections
- Engine & Transmission: Complete teardown and reassembly of the 805cc V-Twin, including valve clearance adjustments (0.08–0.13mm IN / 0.17–0.22mm EX), piston ring service, and 5-speed constant mesh transmission overhaul.
- Fuel Systems: In-depth coverage of both the Mikuni BDSR34 carburetor (early models) and the advanced Electronic Fuel Injection (EFI) systems found on later K5-K9 models, including throttle position sensor (TPS) and ISC valve calibration.
- Shaft Drive: Specialized procedures for the final drive bevel gear, including backlash measurements, shim selection, and universal joint maintenance to ensure smooth power delivery.
- Electrical & Troubleshooting: Full-color wiring diagrams for all regional codes (E-03, E-28, E-33, etc.), ignition coil peak voltage testing (min 200V), and comprehensive "C-Code" diagnostic guides for EFI models.
- Chassis & Suspension: Detailed service for the telescopic front forks and the 7-way adjustable link-type rear suspension, including brake pad replacement and fluid bleeding for the front disc/rear drum setup.
Technical Identification
For accurate parts ordering and registration, this manual identifies the following serial number locations:
- Vehicle Identification Number (V.I.N.): Stamped on the right side of the steering head pipe.
- Engine Serial Number: Located on the right side of the crankcase.
Why This Manual is Essential
Beyond standard repairs, this guide includes the full Periodic Maintenance Chart, listing critical intervals for oil filter changes (3,400ml capacity), spark plug replacement (NGK DPR7EA-9 / DPR8EA-9), and coolant flushes (1,500ml capacity). By following the factory-recommended "Break-In" and service procedures, you protect the longevity of your engine and ensure the reliability of your machine for the long haul.
From the specific torque of the oil drain plug (21 N-m) to complex secondary gear case adjustments, every page of this manual is designed to give the owner or technician the confidence to maintain a Suzuki VL800 with factory-level precision.
Download Instructions for Suzuki Motorcycle Manual
Frequently Asked Questions - Suzuki Motorcycle Manual
Is this manual suitable for beginners?
Yes, this Suzuki manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Motorcycle maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (17.91 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Suzuki Motorcycle manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Are engine specifications included?
This motorcycle service manual includes detailed engine specifications, valve clearances, torque settings, and performance data specific to your Suzuki model.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
Customer Reviews and Feedback
Read what our customers say about this Suzuki Motorcycle manual and share your own experience.
Add Comment
This policy contains information about your privacy. By posting, you are declaring that you understand this policy:
- Your name, rating, website address, town, country, state and comment will be publicly displayed if entered.
- Aside from the data entered into these form fields, other stored data about your comment will include:
- Your IP address (not displayed)
- The time/date of your submission (displayed)
- Your email address will not be shared. It is collected for only two reasons:
- Administrative purposes, should a need to contact you arise.
- To inform you of new comments, should you subscribe to receive notifications.
- A cookie may be set on your computer. This is used to remember your inputs. It will expire by itself.
This policy is subject to change at any time and without notice.
These terms and conditions contain rules about posting comments. By submitting a comment, you are declaring that you agree with these rules:
- Although the administrator will attempt to moderate comments, it is impossible for every comment to have been moderated at any given time.
- You acknowledge that all comments express the views and opinions of the original author and not those of the administrator.
- You agree not to post any material which is knowingly false, obscene, hateful, threatening, harassing or invasive of a person's privacy.
- The administrator has the right to edit, move or remove any comment for any reason and without notice.
Failure to comply with these rules may result in being banned from submitting further comments.
These terms and conditions are subject to change at any time and without notice.
Comments (5)