Suzuki Intruder Volusia - how to take the carburettor out

[@ReverendDrBob]

Im rebuilding my '04 VL 800 (turning it into a bobber) and your videos are helping an extreme amateur like myself learn how pull apart my bike easily. much apperciated. keep up the good work!

[@Maraggie]

+Bob Lloyd Hi Bob, thanks a bunch. I appreciate it. I'm just in the process of recording an almost complete strip-down for post-winter maintenance so perhaps that'll prove useful as well :) Stay tuned and tell your VL800 friends :)

[@Obitron21]

Just subscribed to you, and will tell you why .... today early am my 2003 suzuki vl800 killed its battery attempting to start on a 43 degree morning it took over 12 hours of work to get my bike rumbling again and will let you know right now you are as far as im aware the ONLY KZbinr who does videos for these vl800s and for that I thank you, without your videos today I would have never gotten my bike, my only source of transportation running just wanted to let you know this Floridian appreciates your efforts please keep making them dude its the only help I have thanks again

[@Maraggie]

+Ghost In The Machine Hello. Thank you very much for kind comment. It makes me happy when my videos help others out. I love my VL800 and I will continue to record videos. Any problems, feel free to ask, I will always help out if I can. All the best.

[@Obitron21]

+Maraggie yea no problem dude, waiting on my new choke cable to get here then going from there, will be dropping a jet kit in soon since I removed the stock baffles a bit back

[@Maraggie]

+Ghost In The Machine U sure you need jet kit? I was running mine with Jardine Rumblers without rejet and now recently I was extremely lucky to get V&H Pro Pipe cheap from my friend and I'm not rejetting that either...just some adjustment on the mixture screw. If anything, bike seems more torque'y now.

[@Obitron21]

+Maraggie yes I more want a jet kit for extra power havent had a choke cable in over 2 years so after all my issues yesterday my bikes stock spark plugs were the cause, tips melted

[@Maraggie]

+Ghost In The Machine Fair play. It'll drink more though ;)

[@naterobertson3366]

Another extremely helpful video brother. I just want to tell you how grateful I am for your videos and your guidance and your help I'm doing a 2004 Suzuki Intruder 800cc Volusia. She's the love of my life! God bless you

[@Maraggie]

You're very welcome. Explore my channel...there's a ton of other content you might like.

[@darkstormoutdoors5831]

Great video! Most videos are by people learning as they shoot the video. Your knowledge and teaching approach are a welcome change. Thank you!

[@Maraggie]

Thank you very much. Such feedback means a lot. Best of luck with your bike.

[@floydrturbo1]

Thank you for taking the time to do all the video's you have produced. I used this to take off and clean my carb as I bought it from a woman who had not put in fuel stableizer and/or was running with V$H pipes and had not rejetted carb. Consequently, bike had to be ridden with choke on at least half way minimum and full choke to climb grades. I put stock pipes back on and pulled carb to clean passages after removing all jets and items you show here. I did not immerse carb in cleaner as I left the TPS on, etc. Trying to install carb back on bike I took advice of one of your viewers to put throttle cables back on before clamping back to intake. I haven't been able to get the throttle to return to idle as if carb return spring is not strong enough (but it is very strong off the bike without cables when I twist it by hand). The previous owner kept bike garaged and only has 14,000 miles. I haven't lubed the cables like the manual (Clymer) says as I read they have teflon inner guides that shouldn't be lubed. There are no kinks or severe bends in the cable and throttle returned properly before I removed carb. If anyone has any suggestions short of replacing cables, I'm all ears. Thanks for taking the time to read through all this info. Bike is a 2003 40th Anniv. Edition Volusia Intruder 805.

[@Maraggie]

Hello. First of all, thanks for the feedback, I'm glad I could help. As for the throttle not returning properly... first thing to try is to take off (or loosen) the throttle return cable. Over tightening this one can cause the main throttle cable to get stuck. See if that works and if not, let me know and I'll try to help further.

[@floydrturbo1]

I'll give that a try. I've tried it with a tight return cable thinking that would help the throttle return but no luck. I put my m/c on my m/c stand to put the h/bars straight to make sure that bars aren't turned right or left binding cable although that should not have any effect. The cables are where they were when connected to carb. I'm hooking up cables with carb off intake as one of your readers said to do to make it easer to work on. Great suggestion.

[@monkeywrangler5200]

Add thanks from myself as well. Just learned to ride at 44, got an 02 Intruder with 20k on it and I wanna tackle the carb myself. I do mechanic work on the side but honestly never messed with a bike before and only carbs on small engines till now, so some forewarning on issues is nice to see in your videos. Since I’m a new rider and new to mc repairs, it’s still intimidating me despite a lot of time with cars.

[@Maraggie]

Hi. Once you do it you'll love it. I've lost count how many carbs I've rebuilt now. Have fun.

[@monkeywrangler5200]

@@Maraggie I’ve done a lot of small engine carbs and I’m an automotive mechanic, but when it comes to older cars I let that work go to my brother since that’s more his speed. The Intruder carb looks kind of intimidating to get to and disassemble, but I may try it this winter if things don’t go terrible otherwise and I have free time to mess with the bike haha.

[@Maraggie]

At least it's single, not 4 like I've just done for FJ1200 :D

[@monkeywrangler5200]

@@Maraggie truth to that. Id have 0 clue on syncing carbs haha. Worse comes to worse I have enough biker buddies who can rebuild for me. Learning to ride at 44 has been an adventure

[@duncandavid60]

I found the best way to take the cables off is to uncrew the clamp at the bottom of the carb and lift the whole carb free

[@lanceatkins9660]

Very hard with sausage fingers, but your video was fantastic, thanks. I recommend that you lift the carburettor and then remove the throttle cables. Re-establish them when you put it back in too. Didn't have to fight with them at all, and it made it quite easy.

[@Maraggie]

Thanks for the feedback, really appreciated :)

[@Andon007]

Awesome thanks. Your video helped me out huge andd saved a mechanic bill thank you so much

[@Maraggie]

Cool! I'm glad it helped.

[@jccanada8306]

Thank You.. I Just purchased a 03' Suzuki 800 VL.. and I have to clean the carb.. since Fuel has been sitting it for a Year..... I am sure that its all gummed up .. Now I know how to take the Carb. out..

[@Maraggie]

Happy to help! Good luck getting your bike going.

[@jameshallman6078]

I do the throttle with the carb off the engine and it's a lot easier to remove and install them.

[@erinb5042]

Thank you for sharing knowledge on the intruder!

[@Maraggie]

You're very welcome. I'm glad it helps.

[@serge333666999]

Wow ! I am suscribing to your KZbin's videos. I just saw all what you have done, 1000 thanks.

[@Maraggie]

Welcome and thank you for subscribing. Much appreciated.

[@wakediver]

I like those bars you put on. Jetting my carb now.

[@Maraggie]

Thank you and good luck with jetting!

[@wakediver]

@@Maraggie I watched this video and your next one about taking the carb a lot. They helped immensely. The bike is all back together know and seems to be working really good. Definitely couldn't of done it without you

[@Maraggie]

Success!! I'm really pleased it worked out for you. All the best.

[@chrisapplegate2641]

Thank you for your very informative videos. Very helpful for this novice!!

[@Maraggie]

You're very welcome Chris.

[@serge333666999]

Nice video man ! Thanks a lot, really well explained. Have goods rides to you !

[@gerry9359]

Great video very helpful

[@Maraggie]

Hi Gerry. You're welcome. I hope you'll do great maintaining your bike.

[@metarichard]

Great video Maraggie thanks! I am just about to do this to my 01 Volusia so you have just saved me a ton of time :-)

[@Maraggie]

+Richard Harrison You're very welcome :)

[@phyllishurst5959]

Great Video

[@robinmartin4162]

Got my first 02 Volusia intruder 800 for free all it needs is carb work lol ty

[@Maraggie]

You're welcome :)

[@Scrizzy561]

Love the videos! Any idea why my vl800 will only run with the choke fully out. Idles fine with choke out and can drive it. when I do a hard acceleration though, the bike completely bogs down like it stops getting fuel. I’ve replaced all the jets in the carb.

[@Maraggie]

Hi. Sounds like fuel starvation of sorts. Does it cough and sputter before dying? If it's ok on choke but not without it, it normally means pilot jet is clogged up (even new ones can if there's crap in the bowl). I'd check the pilot and failing that, I'd check the float level - how much does it fill up as it might be insufficient.

[@Scrizzy561]

@@Maraggie so l, it doesn’t actually die. It runs and idles perfect with the choke engaged. It also rides. When accelerating I can only only give it like a quarter throttle before it starts sputtering and bogging down. If I force wide open throttle it just sputters but does not shut off. When back at idle if I disengage the choke, it just immediately shuts off. How would I check float level or be able to test anything else. I’ve replaced jets and sprayed out the port in the carburetor. And replaced spark plugs. And have seafoam running through the carburetor. But it seems to have the same problem that made me originally take the carburetor out. Thanks for the reply!

[@Maraggie]

Float: You measure the float height by using a calipers with the carburettor slanting at an angle of 45° and the float arm just contacting the needle valve. Bend the tongue of the float arm as necessary to bring the height to the value of 7mm (+- 0.5mm) Choke: you're not meant to run on the choke as that's an enrichment circuit that's only good for starting. It bypasses the slow system (idle to slight throttle). When you close choke and it dies, that suggests to me that the normal circuit is not doing its job when petrol is supposed to flow through the components. There's a number of things that can cause what you're experiencing. Simple solutions always first: does it have fresh petrol? are you sure pilot jet didn't clog itself up again? are you certain you've assembled it all correctly? (I've made that boo boo few times) have you changed exhaust and or air filter?

[@robinmartin4162]

I found pulling the cables off when carb is out is easier ....

[@malikuzairkhan738]

thanks sir for your reply .but I want you share any video in intruder 800 cc r any intruder bike. thank you so much sir.

[@serge333666999]

I don't know if you can help me with my problem. This summer I changed my VL800 2004 gas vacuum pump with the hoses related to it. Now it's beginning to be cold outside, around 10-16 Celsius and the bike start at the first crank, keep the idle perfectly and run on the road as usual but one thing is bothering me, when I shift up in gear it give like a small backfire not all the time (sorry for my english, i am french speaking). What do you think it could be ? I read about synchronisation or running too lean... I notice also small kind of back fire on shifting down, not all the time. Or could it be the pair valve system ? Your opinion ? Thanks !

[@Maraggie]

Hi Serge. Your English is great. It can't be synchronisation as you only have one carb. As for running too rich or too lean, it's possible. I assume it was running without backfire before you changed the pump? Do you have standard exhaust and air filter?

[@quebec8]

@@Maraggie I changed vacuum pump and hoses long time ago. So the problem is not there.I think I will check for carb adjustment. But I think I will leave the work to a real mechanic. It does not seem to be easy.

[@quebec8]

@@Maraggie Sorry I forgot, yes stock pipes and Suzuki air filter.

[@Maraggie]

@@quebec8 Maybe the carb just needs cleaning. A little backfire is nothing to worry about really. Is the backfire from exhaust or air filter/carb?

[@gregmeeks2753]

only one carb ? what year ? thank you...great video sir !

[@Maraggie]

Hello Greg. Yes, 2003 VL800, only one carb.

[@berube361]

Is the pilot screw accessible without removing the carb and or tank? Most bikes I've worked on they cant reached with everything on the bike for tuning purposes, for the most part. My 2001 has a set of cobra pipes on and I dont think the carb was jetted. Would like to tweak the pilot screw just slightly so try and smooth out what seems to be a slight lean condition. I know these are lean from the factory anyway.

[@Maraggie]

Hi Jordan. I don't believe so if I remember right. It would be from the left side of the bike but I think it's pointing down too much.

[@denisvolonkin6058]

Is it possible to replace the engine in a Suzuki Intrumer VL400 with a VL800?

[@Maraggie]

Hi. I guess everything is possible it just depends whether the effort is worth it. Personally I haven't seen VL400 in real life to compare size etc.

[@JimmyBackbeat]

You know if anything more than fuel injector was changed in 2005? I'm riding a 2004 VL800, you think the fuel injector of the 2005 will fit my bike? I'm changing pipes quite often and would really want to be able to use a dynojet. As it stands now I'm just running lean when I ride with fat pipes

[@normanbuffett4642]

tip: save removing the throttle cable ends for the last step.

[@Maraggie]

You know what... never crossed my mind hahaha ;D

[@serge333666999]

Is it possible to just do the adjustment without taking the gas tank of the bike ?

[@Maraggie]

You might be able to access pilot screw to adjust mixture from the left side of the bike. I remember there was very little access to do so.

[@serge333666999]

@@Maraggie Now I can figure out more easily with this info and your video, that I watched more carefully. Thank you very much. You are a great source of informations for VL800 fan's, you are very generous !

[@supereveryday9373]

Question about the triple connector from the pair valve. One goes to the petcock the other line to the pair valve where does the third one go? And the vacuum from the fuel pump I was wondering where that goes near carb.

[@Maraggie]

Hi. One to fuel valve, one to pair valve and one to carburettor if I'm not mistaken. Fuel pump I have to admit, I don't remember. Will have a look at manual.

[@supereveryday9373]

Maraggie, Do you know where on the carb? The one on the side of the top cap or the float bowl?

[@Maraggie]

@@supereveryday9373 The one on the float bowl that for petrol. I think it's the one that curves around to the back (you can see it at 14:33)

[@supereveryday9373]

Maraggie thank you answered all my questions. I'm a Harley mechanic and don't do metric bikes often.

[@Maraggie]

@@supereveryday9373 You're very welcome. Got a twincam apart from metrics and I know what you mean.

[@malikuzairkhan738]

hi sir hour you I hope you are well be fine. sir I requested you please upload one video how replacement off timing in Suzuki intruder 1500.cc please.

[@Maraggie]

I'm sorry but I don't have the 1500cc model. :(

[@zackl2774]

What bars/cable kit are you running

[@Maraggie]

Hi Zack. They were 16" narrow base if I remember correctly (I picked ones that were roughly the width of top yoke). Cables I made myself to measure from long kits I bought from ebay.

[@ProfessorChartman]

Great job with this video and I applaud your generosity in sharing it with us! I have a 2004 Intruder Volusia that is leaking fuel right where you removed the fuel hose at 3:23. I don't know the name of the part you pulled it from? Fuel valve, I think? I want to pull the hose off, cut off about an inch then reinstall it. I can pinch the hose while I do this, but won't fuel be leaking from the tank through the fuel valve? Or did you drain the tank thoroughly before beginning this job? And (as long as I'm asking) is there no manual fuel shutoff valve (pet cock) on this bike like most bikes have? Thanks, again, for a great video

[@Maraggie]

Hi Stuart. Really pleased you liked it. Yes, that would be the fuel valve. Like you saw on video, mine didn't leak when I took the hose off. That's because the valve is only supposed to open and let the fuel go when fuel pump creates vacuum. As for your second question, there is no shutoff because of the above... valve won't let fuel out on its own.

[@ProfessorChartman]

@@Maraggie Great! that's what I thought, but wasn't sure. My tank is full and I was afraid to risk pulling off that hose based on my "hunch". I think I will be okay. The leak only happens when the engine is running. Regarding the lack of manual fuel shut-off: I would like to shut that valve and let the engine burn all the fuel in the lines and carb at the end of the season. I don't like fuel sitting in the carburetor all through the off season.

[@Maraggie]

Makes sense... I normally have the carb off for winter cleaning anyway so I never had petrol sat in it :)

[@ProfessorChartman]

@@Maraggie The repair went great; very easy and I saw the split in the hose piece that I cut off. THANK YOU! If I can pick your brain just once more? ... There is a knob thing right near where I was working and I think I saw it at 14:15. Did I hear you call it an Idle control? Can I tweak the idle up "just a touch" by turning it clockwise?

[@Maraggie]

@@ProfessorChartman Yes mate, that's what it's for. When you turn it, it basically opens/closes the butterfly which will increase/decrease your idle.

[@codys7703]

Do I need to drain the tank of gas before removing?

[@Maraggie]

Hi Cody. No you don't. When I removed the hose at 03:20 I had fuel in my tank.

[@codys7703]

Cool, thanks

[@samn5362]

would this work for a 2001 suzuki intruder vs 800 gl?

[@Maraggie]

Hello Sam. I'll be honest and say that I'm not sure as I haven't seen the arrangement on VS800. Should be similar though I'd think. Sorry I can't be of much help.

[@alexadams4382]

13:31 what is he holding mine is unplugged and can’t find other end to it now bike isn’t running right

[@Maraggie]

HI Alex. Those three connectors? They're heater terminal lead wires. They connect to main loom (white connector as shown on video)

[@yoshizimmerman3950]

US model doesnt have them

[@samn5362]

does this work for the 2001 Suzuki intruder vs 800 gl

[@Maraggie]

Hi mate. I must admit I don't know. I would guess it's similar. Seat and tank will have to come off most likely. Let me know how you get on. All the best.

[@samn5362]

thanks i am hopping that i will not have to spend over $1000 on parts.

[@Maraggie]

Is your carb playing up then? A good clean and fresh set of jets will do the trick nicely ;)

[@samn5362]

i am not getting any fuel to the engine it is running in to the carb and going out of the over flow and spitting gas every where

[@Maraggie]

That sounds like a very simple fix. You need to check your float. Almost sounds like the valve that hangs of it fell off somehow. Either that or the rubber end of the valve is very worn and it never fully closes when bowl fills up, hence the overflowing. I had that on my chop.

[@jaredb6418]

I am looking to replace those plastic pieces surrounding the ignition that you had to take off. I can't find those anywhere, would you happen to know where I could get them?

[@Maraggie]

Hello Big Foot. Do you mean the neck covers? Just search ebay for "vl800 neck covers" and you'll find them no problem.

[@jaredb6418]

awesome, thanks.

[@Maraggie]

You're welcome ;)

[@andrewrudkovsky4725]

clutch cable coming to carburetor... hmm, interesting... insidious japanese

[@Maraggie]

You know what... 6 years after I've done the video and I never noticed I said that... Brilliant, I'll have a clutch operated carb anytime :D

[@ronniefrutschi2011]

How the hell do people do mechanic work with gloves?

[@Maraggie]

With no effort at all.

[@ronniefrutschi2011]

Maraggie I can’t, seem to get in my way

[@Maraggie]

@@ronniefrutschi2011 I know what you mean. They tear way too quickly too. I avoid them when I can but when I need to keep my hands clean for later, it saves a lot of time.

[@Seldomane]

all I want to know is where the carb is at to try spraying a dash of carb cleaner as it wont start after winter.... why do mechanics only explain things in ways that other mechanics would understand? "So you want to clean your carb? Well first lets take the engine out..." pff.

[@Maraggie]

Hello Luthien. I'm not sure I understand your issue. Video clearly shows that carb is tucked tight under the petrol tank and there is no way to remove it without removing the tank first. I'm sorry the video wasn't descriptive enough.

[@serge333666999]

I spray starter fluid directly where the air filter is connected. Just remove the air filter and spray inside, where the carburator is...it take a few shots only. If it does not start, try again. It ALWAYS work.