2005 Suzuki VL800 Volusia Motorcycle Supplementary Service Manual

Wiring diagrams, specifications, and repair sequences for the VL800 Volusia: fuel system, emission control, and electrical diagnostics. Part number 99500-39050-032.

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Document Details

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Document Number / Seller:
24561 / Sandra Stewart
File Size:
45.16 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 21, 2025

Models Covered & Key Technical Specifications

Structured Specification Repair Manual: Suzuki VL800 Volusia (99500-39050-032) • 2005 edition Technical-Guide

Diagnostic and repair information | Series Section.

  • Engine Specifications: 805 cc, 49.12 ci, V2, four-stroke, 51.0 HP (37.2 kW) establishes the core power output Architecture.
  • Fuel System: For optimal fuel delivery, 3.0 kgf/cm², 300 kPa (43 psi) defines the maximum fuel pressure Requirement.
  • Transmission: Wet multi-plate, 5-speed constant mesh -- signifies the gearbox configuration Threshold.
  • Brake System: Front and rear disc brakes require specific maintenance procedures Logic.
  • Electrical System: Ignition timing is critical for smooth operation Configuration.
  • Emissions Control: Evaporative emission control system inspection is detailed Parameters.

Professional Workshop Service Manual & Technical Specifications

Structured Specification Repair Manual: Suzuki VL800 Volusia supplementary manual, 2005 edition Technical-Guide

Series-Validation: VL800 Volusia / Suzuki Motor Corporation // Year-Coverage: 2005 / Motorcycle // Series-Validation: Supplementary Service Manual.

Suzuki VL800 Volusia (99500-39050-032) - 2005 Edition

Integrated-Framework Baseline Calibration-Standards
Engine 805 cc V-twin 51.0 HP (37.2 kW)
Fuel System Approx. 300 kPa (43 psi) 5-speed transmission
Electrical Electronic Ignition LED lighting

Coverage is segmented into the following sections:

  • Periodic Maintenance Chart
  • Fuel Delivery System
  • Electrical System
  • Emissions Control
  • Troubleshooting Guides

Repair information is provided for the fuel injection system, ignition system, and emissions control systems. The document includes coverage of engine specifications, drivetrain components, and chassis systems. Brake system specifications are included for front and rear brakes. Safety procedures are documented for routine maintenance. Fluid capacities are listed for engine oil, coolant, and brake fluid. This manual provides a detailed configuration of the VL800 Volusia.

This manual documents torque specifications for critical engine and chassis components to ensure proper bolt stretch prevention.

FAQ

Calculate the **precise** pressure specifications for the fuel system. keyboard_arrow_down

300 kPa (43 psi) at 3.0 kgf/cm² is the specified fuel pressure for the VL800 Volusia.

What values are **proper** for the brake system? keyboard_arrow_down

Front and rear disc brakes are specified for the VL800 Volusia, with specific torque values detailed in the chassis section.

Assess the **standard** service interval parameters for the engine. keyboard_arrow_down

Engine oil and filter changes are recommended every 6,000 km (4,000 miles) or 12 months, whichever comes first. Spark plugs should be inspected at 6,000 km (4,000 miles) intervals.

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The service manual was easy to download, and the email with the link arrived promptly. Highly detailed and a must-have for maintenance!
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I found this manual incredibly helpful. The support team responded quickly when I had a question, making the whole experience smooth. Definitely recommend!