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  Suzuki Volusia 2001-2004 and Suzuki Boulevard C50 2005-2008 Repair Manual
  Suzuki Volusia 2001-2004 and Suzuki Boulevard C50 2005-2008 Repair Manual
 
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Product Code: CL-M260-2

Features
 
 
Features
This repair and service manual covers Suzuki Volusia 2001-2004 and Suzuki Boulevard C50 2005-2008.

Table of Contents

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

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
PRODUCT DETAILS:
  • Publisher: Clymer Manuals - 2009
  • Author: Mike Morlan
  • Binding: Paperback - 7 x 10 inches
  • Pages: 422 - Hundreds of b&w photos and illustrations
  • ISBN: 9781599692883

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