🏷️ Basic Information Identification Make: Suzuki Model: VL800 Intruder Model Designation: Intruder Volusia Generation Generation Code: C50 Boulevard Codes Chassis Code: WVBM 👋 Introduction Market Position Segment: Cruiser Motorcycle Intended Use: Cruising, touring, everyday riding. Competitive Analysis Key Competitors: Honda Shadow, Yamaha V-Star, Kawasaki Vulcan. Key Features Engine Configuration: V-twin, 45-degree cylinder angle. Styling: Classic cruiser aesthetics with flowing lines and chrome accents. Handling Characteristics: Comfortable and stable ride, suitable for longer distances. Manual Value Proposition: Enables owners to perform professional-level maintenance and repairs, saving on dealership costs. 📋 Manual Details Coverage Areas Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Page Count Total Pages: 638 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, assembly, disassembly, lubrication system, fuel system, ignition system, exhaust system. Transmission: Gearbox disassembly and assembly, internal components, lubrication. Electrical System: Wiring diagrams, lighting, ignition, starting system, charging system, instrumentation. Bodywork: Frame, fairings, fenders, seat, controls, chassis components, removal and installation. Suspension And Steering: Front forks, rear shock absorbers, steering system, wheel alignment. Braking System: Brake fluid replacement, caliper overhaul, master cylinder, brake line maintenance. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, lubrication, tune-ups, fluid checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding charts. Repair: Detailed step-by-step instructions for component repair and replacement. Overhaul: Complete disassembly and reassembly procedures for major components. Installation Removal: Procedures for removing and installing various parts and assemblies. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced engine and transmission rebuilds. Target Audience: Professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable Binding Type Binding: Digital (PDF) Paper Type Media: Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin, SOHC, 8-valve Displacement: 805 cc (49.1 cu in) Bore X Stroke: 83.0 mm x 75.0 mm Cooling System: Liquid-cooled Compression Ratio: 9.3:1 Performance Horsepower Estimate: Approx. 53 hp @ 6,500 rpm (manufacturer data may vary) Torque Estimate: Approx. 70 Nm (52 lb-ft) @ 5,000 rpm (manufacturer data may vary) Fuel System Fuel Delivery: Fuel Injection (Suzuki Dual Throttle Valve - SDTV) Fuel Type: Unleaded gasoline Fuel Tank Capacity: 16.0 L (4.2 US gal) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch: Wet multi-plate Final Drive: Shaft drive Features Gear Ratios: Detailed in manual (e.g., 1st: 2.64, 2nd: 1.79, 3rd: 1.30, 4th: 1.04, 5th: 0.86) 📐 Dimensions Exterior Overall Length: 2,420 mm (95.3 in) Overall Width: 925 mm (36.4 in) Overall Height: 1,105 mm (43.5 in) Wheelbase: 1,670 mm (65.7 in) Ground Clearance: 135 mm (5.3 in) Weights Dry Weight: 214 kg (472 lbs) Curb Weight: 231 kg (509 lbs) Gross Vehicle Weight Rating: Not specified, consult owner's manual or service manual. 🛡️ Safety Features Ratings Safety Certifications: Meets relevant national and international motorcycle safety standards. Active Features Braking: Front: Disc, Rear: Disc (some models may have variations) Lighting: Halogen headlight, LED tail light. Passive Features Frame Construction: Steel frame for rigidity and stability. Warning Symbols: Manual utilizes WARNING, CAUTION, and NOTE designations for critical safety information. 💡 Technology Features Infotainment Audio System: Not typically equipped with a factory-installed audio system. Instrumentation: Analog speedometer, tachometer, fuel gauge, indicator lights. Driver Assistance ABS: Not available on this model. Connectivity Charging Ports: Optional accessory charging ports may be installed. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact details). Spark Plug Replacement: Refer to manual for mileage-based replacement intervals. Chain Maintenance: Not applicable, as the VL800 Intruder utilizes a shaft drive. Fluid Specifications Engine Oil Type: API SG, SF, SE or higher, SAE 10W-40, JASO MA certified motorcycle oil (specific viscosity may vary based on climate). Engine Oil Capacity: Approx. 3.2 L (3.4 US qt) with filter change (refer to manual for precise capacity). Brake Fluid Type: DOT 4 brake fluid. Coolant Type: Permanent type antifreeze coolant (ethylene glycol based, 50% mixture with distilled water). Final Drive Oil Type: Hypoid gear oil API GL-5, SAE 80W-90. Known Issues Common Wear Items: Brake pads, tires, battery, clutch plates (depending on usage). Potential Problems: Fuel pump issues, stator coil failures (rare but documented), carburetor synchronization (if applicable on earlier models before fuel injection). Special Tools Required Tools: Torque wrench, specific Suzuki factory tools (identified by numbers in the manual), standard metric toolset. 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation, a renowned Japanese manufacturer of automobiles and motorcycles. Model Evolution Predecessor: VL1500 Intruder LC. Rebranding: In 2005, Suzuki rebranded the Intruder models under the 'Boulevard' name. The VL800 became the Boulevard C50. Production Production Period: 2001-2009 (for this specific manual coverage). Manufacturing Location: Japan (typically for Suzuki motorcycles). 🏆 Awards & Recognition Recognitions Industry Acclaim: Consistently...