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Suzuki Boulevard C50 2001-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: Boulevard C50 Model Designation: Intruder Volusia (previous generation name) Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Codes Engine Code: V9M (typically designated by model, not specific engine code in this context) 👋 Introduction Market Position Market Segment: Cruiser motorcycle Target Audience: Riders seeking a comfortable, classic-styled cruiser with reliable performance Competitive Analysis Key Competitors: Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series Key Features Styling: Classic cruiser styling with teardrop fuel tank, pulled-back handlebars, and comfortable riding position Engine Type: V-twin, liquid-cooled, SOHC, 8-valve Drivetrain: Shaft drive, contributing to low maintenance Fueling: Fuel injection (Suzuki Dual Throttle Valve - SDTV system) 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Primary Coverage: Mechanical, electrical, and body repair and maintenance Page Count Page Count: 638 Language Language: English Format File Format: PDF Download Method: Instant Download Compatibility: Windows, Mac, Linux OS 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, piston, crankshaft, valve train, lubrication system Fuel System: Fuel injection system, fuel pump, injectors, throttle body, fuel lines, fuel tank Ignition System: Ignition coils, spark plugs, ignition control module Transmission: Clutch, gearbox, final drive (shaft drive) Cooling System: Radiator, fan, thermostat, coolant hoses Exhaust System: Exhaust pipes, mufflers, gaskets Brake System: Front and rear brakes, brake lines, master cylinders, calipers, pads, fluid Suspension System: Front forks (telescopic), rear shock absorbers, linkages Steering System: Handlebars, steering head bearings Electrical System: Battery, charging system (alternator, rectifier/regulator), lighting, starting system, wiring diagrams Body And Frame: Chassis, body panels, fuel tank, seat, fenders, mounting hardware Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Troubleshooting: Diagnosis of common problems, electrical system troubleshooting, engine performance issues Repair: Component removal, disassembly, repair, reassembly, and installation Adjustments: Carburetor (if applicable to earlier models, though C50 is EFI), clutch, brakes, suspension, idle speed Diagnostics: System checks, fault code interpretation (if applicable) Technical Depth Depth Level: Comprehensive, step-by-step procedures for both DIY enthusiasts and professional mechanics Diagnostic Charts: Included for troubleshooting common issues Pictorial Diagrams: Detailed illustrations, exploded diagrams, drawings, and photos Service Data: Includes service data, specifications, and allowable limits Special Tools: References and illustrations for special service tools 📊 Manual Specifications File Format PDF Quality: High-resolution, ensuring clarity of text and images Searchable Text: Likely, as is standard for quality PDF manuals, allowing keyword searches Print Quality Printable: Yes, all pages are printable Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, 45-degree V-twin Displacement: 805 cc (49.1 cu in) Bore X Stroke: 97.0 mm x 90.0 mm (3.82 in x 3.54 in) Valvetrain: SOHC, 2 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approximately 50-55 HP (specific dyno figures vary) Torque: Approximately 48-52 lb-ft (specific dyno figures vary) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Suzuki Dual Throttle Valve (SDTV) Fuel Tank Capacity: 4.1 US gal (15.5 L) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Final Drive: Shaft drive Clutch: Wet multi-plate 📐 Dimensions Exterior Overall Length: 9.1 ft (2350 mm) Overall Width: 2.8 ft (870 mm) Overall Height: 3.7 ft (1120 mm) Wheelbase: 5.1 ft (1565 mm) Weights Dry Weight: Approximately 498 lbs (226 kg) Curb Weight: Approximately 540 lbs (245 kg) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings are not typically standardized like automotive) Active Features Active Safety: Responsive braking system, predictable handling Passive Features Passive Safety: Sturdy frame construction 💡 Technology Features Infotainment Infotainment Features: Basic analog speedometer and tachometer, odometer, trip meter, fuel gauge. No integrated infotainment system. Driver Assistance Driver Assistance Systems: N/A (Motorcycle) Connectivity Connectivity Features: N/A (Motorcycle) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals, typically every 3,000-5,000 miles or annually Spark Plug Replacement: Refer to manual, typically around 7,500-15,000 miles Brake Fluid Change: Refer to manual, typically every 2 years or as per condition Fluid Specifications Engine Oil Type: API SG, SH, SJ, SL rated motorcycle oil, SAE 10W-40 recommended (verify in manual) Engine Oil Capacity: Approx. 2.8 L (2.9 US qt) without filter change, 3.0 L (3.2 US qt) with filter change (verify in manual) Coolant Type: High-quality ethylene glycol based antifreeze coolant, Suzuki recommends 50/50 mixture with distilled water Brake Fluid Type: DOT 4 (verify in manual) Final Drive Oil Type: API GL-5, SAE 80W-90 hypoid gear oil (verify in manual) Known Issues Common Issues: Potential for stator/rectifier failure (common on many bikes of this era), occasional electrical connector corrosion, clutch drag (can be addressed with proper adjustment and maintenance) 📚 Vehicle History Brand Heritage Brand Focus: Suzuki has a long history of producing reliable motorcycles across various categories Model Evolution Predecessor: Suzuki Intruder Volusia Rebranding: Rebranded as Boulevard C50 starting in 2005 to...
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Suzuki Boulevard C50 2001-2009 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
Boulevard C50
Model Designation:
Intruder Volusia (previous generation name)
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Codes
Engine Code:
V9M (typically designated by model, not specific engine code in this context)
👋 Introduction
Market Position
Market Segment:
Cruiser motorcycle
Target Audience:
Riders seeking a comfortable, classic-styled cruiser with reliable performance
Competitive Analysis
Key Competitors:
Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series
Key Features
Styling:
Classic cruiser styling with teardrop fuel tank, pulled-back handlebars, and comfortable riding position
Engine Type:
V-twin, liquid-cooled, SOHC, 8-valve
Drivetrain:
Shaft drive, contributing to low maintenance
Fueling:
Fuel injection (Suzuki Dual Throttle Valve - SDTV system)
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Primary Coverage:
Mechanical, electrical, and body repair and maintenance
Page Count
Page Count:
638
Language
Language:
English
Format
File Format:
PDF
Download Method:
Instant Download
Compatibility:
Windows, Mac, Linux OS
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, cylinder head, piston, crankshaft, valve train, lubrication system
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel lines, fuel tank
Ignition System:
Ignition coils, spark plugs, ignition control module
Transmission:
Clutch, gearbox, final drive (shaft drive)
Cooling System:
Radiator, fan, thermostat, coolant hoses
Exhaust System:
Exhaust pipes, mufflers, gaskets
Brake System:
Front and rear brakes, brake lines, master cylinders, calipers, pads, fluid
Suspension System:
Front forks (telescopic), rear shock absorbers, linkages
Steering System:
Handlebars, steering head bearings
Electrical System:
Battery, charging system (alternator, rectifier/regulator), lighting, starting system, wiring diagrams
Body And Frame:
Chassis, body panels, fuel tank, seat, fenders, mounting hardware
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Troubleshooting:
Diagnosis of common problems, electrical system troubleshooting, engine performance issues
Repair:
Component removal, disassembly, repair, reassembly, and installation
Adjustments:
Carburetor (if applicable to earlier models, though C50 is EFI), clutch, brakes, suspension, idle speed
Diagnostics:
System checks, fault code interpretation (if applicable)
Technical Depth
Depth Level:
Comprehensive, step-by-step procedures for both DIY enthusiasts and professional mechanics
Diagnostic Charts:
Included for troubleshooting common issues
Pictorial Diagrams:
Detailed illustrations, exploded diagrams, drawings, and photos
Service Data:
Includes service data, specifications, and allowable limits
Special Tools:
References and illustrations for special service tools
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, ensuring clarity of text and images
Searchable Text:
Likely, as is standard for quality PDF manuals, allowing keyword searches
Print Quality
Printable:
Yes, all pages are printable
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, 45-degree V-twin
Displacement:
805 cc (49.1 cu in)
Bore X Stroke:
97.0 mm x 90.0 mm (3.82 in x 3.54 in)
Valvetrain:
SOHC, 2 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 50-55 HP (specific dyno figures vary)
Torque:
Approximately 48-52 lb-ft (specific dyno figures vary)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Suzuki Dual Throttle Valve (SDTV)
Fuel Tank Capacity:
4.1 US gal (15.5 L)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Features
Final Drive:
Shaft drive
Clutch:
Wet multi-plate
📐 Dimensions
Exterior
Overall Length:
9.1 ft (2350 mm)
Overall Width:
2.8 ft (870 mm)
Overall Height:
3.7 ft (1120 mm)
Wheelbase:
5.1 ft (1565 mm)
Weights
Dry Weight:
Approximately 498 lbs (226 kg)
Curb Weight:
Approximately 540 lbs (245 kg)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are not typically standardized like automotive)
Active Features
Active Safety:
Responsive braking system, predictable handling
Passive Features
Passive Safety:
Sturdy frame construction
💡 Technology Features
Infotainment
Infotainment Features:
Basic analog speedometer and tachometer, odometer, trip meter, fuel gauge. No integrated infotainment system.
Driver Assistance
Driver Assistance Systems:
N/A (Motorcycle)
Connectivity
Connectivity Features:
N/A (Motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals, typically every 3,000-5,000 miles or annually
Spark Plug Replacement:
Refer to manual, typically around 7,500-15,000 miles
Brake Fluid Change:
Refer to manual, typically every 2 years or as per condition
Fluid Specifications
Engine Oil Type:
API SG, SH, SJ, SL rated motorcycle oil, SAE 10W-40 recommended (verify in manual)
Engine Oil Capacity:
Approx. 2.8 L (2.9 US qt) without filter change, 3.0 L (3.2 US qt) with filter change (verify in manual)
Coolant Type:
High-quality ethylene glycol based antifreeze coolant, Suzuki recommends 50/50 mixture with distilled water
Brake Fluid Type:
DOT 4 (verify in manual)
Final Drive Oil Type:
API GL-5, SAE 80W-90 hypoid gear oil (verify in manual)
Known Issues
Common Issues:
Potential for stator/rectifier failure (common on many bikes of this era), occasional electrical connector corrosion, clutch drag (can be addressed with proper adjustment and maintenance)
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki has a long history of producing reliable motorcycles across various categories
Model Evolution
Predecessor:
Suzuki Intruder Volusia
Rebranding:
Rebranded as Boulevard C50 starting in 2005 to align with Suzuki's Boulevard cruiser line
Production
Manufacturing Origin:
Japan (typically)
🏆 Awards & Recognition
Recognitions
Recognitions:
Consistently praised for its comfortable ride, smooth power delivery, and value for money in the cruiser segment.
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