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Suzuki Volusia (2001 - 2004)

Complete coverage for your vehicle

Written from hands-on experience gained from the complete strip-down and rebuild of a Suzuki Volusia, Haynes can help you understand, care for and repair your Suzuki Volusia. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Suzuki Volusia can help maintain its resale value, save you money, and make it safer to ride.

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Choose the Haynes manual that is right for you with our complete comparison guide Printed manualThe original and best, delivered to your door Online manualA feature-loaded digital edition of the original manual
Maintenance schedule Simple weekly checks and servicing guides to keep you on the road Printed manual Digital manual
Comprehensive procedures Guide you through every step from minor adjustments to major overhaul Printed manual Digital manual
Fully illustrated With hundreds of photos Printed manual Digital manual
Hints and practical advice From the DIY experts provide inside information Printed manual Digital manual
Specifications and data Enable testing and measuring for wear Printed manual Digital manual
Wiring diagrams Enable tracing of electrical faults Printed manual Digital manual
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Printed manual

The original and the best, delivered to your door
$36.95
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Online manual

All the content of a printed manual, plus much more
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What's covered

What's covered: 
Suzuki Volusia, 2001-2004
Suzuki Boulevard C50, 2005-2017

Table of contents

This Suzuki motorcycle manual is 440 pages.

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 / Engine oil and filter change / 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 removal and installation / 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 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 / Electronic control module ECM / Starter system / Starter relay / Lighting system / Switches / Relay assembly / Speedometer / Horn / Cooling system / Fuses / Wiring diagrams / Specifications

CHAPTER ELEVEN / 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

COLOR WIRING DIAGRAMS

Models covered:
2005 2006 2007 2008 2009 2010 2011 Suzuki Boulevard C50
2001 2002 2003 2004 Suzuki Volusia

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Clymer Manuals Suzuki Boulevard C50 Manual
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Clymer Manuals Suzuki Volusia Manual
Clymer Manuals Suzuki Manual

Print manual

More details
Part number: 
CM2603
ISBN-13: 
9781620923184
Language: 
English
# of pages: 
440
Publication date: 

Online manual

More details
Part number: 
ECM2603
Language: 
English

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  • All colour step-by-step guides for over 200 jobs with 700+ photos
  • Image zoom feature for close-up view of jobs
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  • Troubleshooting section – quickly find the cause of a problem
  • Colour wiring diagrams help track problems quickly and easily
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  • Dictionary of automotive terms
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  • Conversion calculator – imperial and metric units