Suzuki Intruder Volusia VL800 - Maintenance workshop part #1 - disassembly

[@oepolish]

I using this series as a guide to restore mine from a bobber, back to a cruiser.

[@Maraggie]

Awesome. Good luck with it.

[@dennismims2999]

I found your channel a couple of years ago and saved all of your maintenance videos. It goes without saying that the Volusia is the best and most reliable bike I've ever owned. As of about 2 years ago it finally came to the point where I needed to put it in the shop for a major repair but with the help of your videos that was the first time and the last (I hope). Recovery from heart surgery was what kept me from doing the stator and regulator/rectifier . I've ridden it solo in Fl, Ga, Tn, Al, Ms, La and Tx. I've also spent many miles riding 2 up. Thanks for all of the information and sharing your knowledge. I've not seen any videos from you in quite some time regarding the Volusia but I hope you're still out there on something with 2 wheels. Thanks.

[@Maraggie]

Hello Dennis. First of all, thank you for visiting and kind words, I appreciate it. I'm glad the videos help. It took a lot of work to put the whole series together but it's been worth it. Reason behind no new videos on Volusia is because it's gone to someone else now. I've focused on custom fabrication and custom bikes now. And yes, of course I got 2 wheels... Currently an XS650 (that I haven't shown off yet), twinkie and FJ12 that I'm building. I hope to start uploading more videos again as I sort my workshop out (having recently moved houses). So stay tuned :)

[@dennismims2999]

@@Maraggie I'll be on the lookout for new videos.

[@Unboxed_pokemon]

I appreciate you putting these videos out. The dealership has struggled to assist me with my bike and i am hoping to figure out why the previous owner put a clamp on filter on the carburetor. I have just enough knowledge to really screw myself lol

[@Maraggie]

Hi. You're very welcome, I'm glad they're still helping people. A clamp on the filter...interesting... is it a wide clamp? My first thought is that he tried to restrict the amount of air going into the carburettor - which equals to enriching the mixture.

[@zukins5003]

I have a 2016 c50 and can't wait to watch all your videos, thanks and subbed. Keep it coming

[@Maraggie]

You're welcome :)

[@realman88cheerleader]

Your videos have VERY much helped me with my 2003 suzuki volusia 800!! Could you point me in the direction of a "how to video" for changing the coolant?

[@Maraggie]

I'm glad to hear that :) You're welcome. I don't think I've done coolant replacement but it's easy. When it's all cold, remove the filler cap (under the tank), then disconnect a thick hose on your left hand side front, just behind the radiator, and drain the coolant. Then you can flush with water (never did that). Reconnect the hose and start slowly pouring in the fresh coolant via the filler on top. Once in a while, rock your bike from left to right as this will release air trapped in the system. Keep topping up and keep rocking the bike. If the coolant level is high enough so you can see it, and it doesn't drop anymore when you rock the bike, put everything back together and fire the bike up. Give it a minute, switch off, let it cool down (or it will spray you with hot coolant!) and then check if the level dropped. Top it up and repeat if necessary.

[@PoloCarrera-yq9vr]

Love your video really helpful. My bike it’s missing a few bolts the rear fender … could you point me in the right direction when it comes to the right sizes for the bolts 🙏

[@Maraggie]

Hello. Thanks for stopping by, much appreciated. I'm afraid I'm unable to check the bolt sizes now as the bike has gone to the next owner a while back. Hopefully someone will see this comment and assist.

[@thefunnywolf]

Your video is very helpful. Thanks mate

[@Maraggie]

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

[@VikingBagsYT]

Enjoyed the video! great work on the content!

[@Maraggie]

Hi. I'm glad you enjoyed it, thank you.

[@groovedrummer8235]

Great video

[@crgehi5866]

Great 👌...I also own a VL800 and would like to add Ape handlebars just like here! On the subject of clutch cable, brake cable and throttle cable, do the originals fit or do everything need to be replaced? I'd appreciate every answer or assistance regarding

[@Maraggie]

Hi. Depends how high you want to go. I had to replace the cables with longer ones for the apes I had. These were 16 or 18 inch. Can't recall now, sorry. You should be able to get universal kits for both, trim to required length and install.

[@Frank-kw3tq]

Thanks for the useful info

[@Maraggie]

I'm glad I could help.

[@leeyork5473]

Hey, this is lee from OKC Oklahoma,I really appreciate you,sharing your videos with us..they’ve been a great help! I was wondering,if by any chance you could share your thoughts or the process,installing the ape hangers, like the ones you have. It would,be most appreciative, thanks.

[@Maraggie]

Hi Lee, thank you very much for your feedback. I'm happy the videos help brothers from across the pond. With regards to the apes, there's not much to it really. You will just need a) longer cables (depending on how tall you want them). You can buy universal cable kits that are longer than needed, cut them down, solder the ends (I recommend plumber's solder) and b) longer electric cables (just extend the stock ones). My apes had slots so I guided it all inside for a tidy look. I don't have the VL anymore and I must say I miss it... but I'm keeping very busy, currently in possession of custom HD and XJR1300, and three FJ1200 engines waiting to be built. Soon I should start posting a lot of build videos and I will cover a lot of aspects, some will hopefully help you and give you ideas for your own bike. All the best and don't hesitate to get in touch if you need more info.

[@christiangarcia5876]

Nice paint. Among a bunch of other crap, I took the pair and canister out but I’m curious if I can take the vacuum petcock out too without problems starting or down the road later. What do you think?

[@Maraggie]

Hi Christian. Do you mean take it out and ride without it?

[@christiangarcia5876]

@@Maraggie yes

[@Maraggie]

@@christiangarcia5876 I see. I've never tried it and I'm not sure if it would affect how fuel pump works. If you take the vacuum petcock out, you're turning it into gravity fed system effectively and all that petrol will be going to pump, whether there is demand or not.

[@jasonnolan5898]

Hey man I've seen all ur videos on ur suzuki volusia , ur very smart and u helped me with alot of installation but a tear ago I repainted my 03 and it would not turn on not even light up so I checked the fuses nothing there I replaced the relay solenoid the bike lights up but that's it there's no click and no other nose when I try to start it do you have any thoughts on what I'm not seeing or over looking ... your help would be amazing thank you . Sincerely Jason from VT

[@Maraggie]

Hi Jason. Considering your battery is OK, I would probably guess that when you were repainting it (you didn't say the extent so I'm guessing), you painted the bits on frame/engine where you got earth cable(s) connecting. It sounds like you lost earth. Check this first as it might be a very easy solution. Let me know how you get on mate.

[@jasonnolan5898]

Thank u that's what I'll be doing next very much appreciated

[@GiriKumar]

Which lift is that? Looks sturdy and well built. Thanks for the video...

[@Maraggie]

Hi. It is very good and still serves me well. I did a review here: kzbin.info/www/bejne/jai5e3-fpqaomdE I think you can still get them, just make sure you get the wider version.

[@bommel4343]

Top👍very, very good

[@Maraggie]

Thank you Jo, I appreciate it a lot.

[@Frank-kw3tq]

Can I replace the seat without the rear fender and braces I like that look a lot or is the rear fender vital for the seats function

[@Maraggie]

Stock seat is, yes, it bolts into the fender.

[@rtula7882]

Just found you channel, I have a 2004 volusia. Have you done a video on changing your handlebars?

[@Maraggie]

Hi Rick. I'm afraid not, sorry.

[@paimoon945]

Hey bro love your channel I have this bike so it’s really awesome information my question is is there any thing I need to think about removing the enginine cover I’ve watched all your vids and I don’t think you do it?

[@Maraggie]

Hi. Which cover? Rocker cover?

[@paimoon945]

@@Maraggie ummm not sure what you call it the chrome part where you put the oil in? Anyway I pulled it off today as I wanted to paint it black btw that’s why I’m dismantling and then oil spilled out everywhere 😔😔🥺 I really don’t know what I’m doing so I just put it back on 😂 freaked out a bit is there anything I need to consider ?? How much oil do I need to refill? I have removed the pipes so I can wrap them and have started to paint over all of the chrome parts on the bike that are not heat affected if that makes sense any advice be cool 😀

[@Maraggie]

Morning. That sounds like clutch cover. Oh dear :) I congratulate you though on having a go. Since you spilled oil, you won't know exactly how much to put back in so it's a good idea to replace all of it. I think VL800 takes 3 liters but I will check. Drop the oil and then you will be able to take all covers off for painting. Things to consider...hmm definitely the gaskets/seals for the covers. You should be able to re-use them if they're in good condition. If not, I recommend getting new ones. Another thing to consider is, when you'll be putting the covers back on, the bolt tightening sequence and torque. You want to make sure that the covers are on properly to avoid leaks. In "About" section of my channel there's my email. Send me a message and I will give you full service manual for VL800. That should help.

[@paimoon945]

@@Maraggie oh no bolt tightening sequence? I thought I might be in over my head😂😅 and if the gasket thing your talking about is like a thin piece of lining that goes around the edge of the case then yep I broke it 😂 re the clutch case do you know if I have to use a heat resistant spray ? Thanks for the advice I’ll send through an email

[@paimoon945]

@@Maraggie just checked the about on your channel couldn’t find your email?

[@0neduke]

Hey man thanks for the videos. I’m wondering if you have any advice how the fk I can take off that nut I in the frame of the back fender. Frustrating I’m trying to take my saddlebag off

[@Maraggie]

Hi. Do you refer to the one I talk about in the video as being a bit tough to undo? They can be a bit problematic. If they've been on for a long time, chances are the nuts on inside rusted up. Get your hand under the fender and feel where the mount is... you should be able to get a spanner in there to hold it while you try to undo the allen bolt. Might need some leverage. Might be worth soaking them with penetrating oil of sorts as well.

[@0neduke]

@@Maraggie hey thanks for the response man. yes. 2004 model not the best of maintaining on it, very rust bolts it wa shard to get out but I did it with some ratchets. Do you have any recommendation on penetrating oil

[@Maraggie]

@@0neduke Hi. I'm just testing Seafoam Deep Creep and it seems quite alright. Lingers a long time which is great for penetration. I don't have an absolute favourite though...yet.

[@GiulianoAlmeida]

very nice! help me a lot! thx :)

[@Maraggie]

You're welcome Giuliano! :)

[@robertovalentin1482]

Hi I know by this time you my not have the bike but I needs to know if I can bye any handlebar for my c50 or do I need to buy a specific size to fit my risers

[@Maraggie]

Hi Roberto. As long as they are the right size for your risers (either 1" or 7/8") then you're fine. You can always change the risers too really, then you can do any size you want.

[@robertovalentin1482]

Cool thanks good day

[@norbertbulot443]

Bonjour je n'arrive pas à enlever siège passager comment procéder merci

[@holgercars3489]

helle, what exhaust is this? Hope to find this one in germany!!! thx

[@Maraggie]

Hello. It's Vance & Hines Pro Pipe. Best sounding exhaust for VL800 in my opinion.

[@brianhunt7161]

I have a ❓ my 02 Volusia 800 runs ruff when plug wire is completely on plug, pull it off halfway of plug it runs fine! Any thoughts?

[@Maraggie]

Hi Brian. I assume you mean choke cable. If the bike runs on choke but dies without it, it's likely that pilot jet in carb is blocked up. That's assuming that it was always fine and nothing was changed since it started playing up.

[@normanbuffett4642]

you have a custom exhaust which looks great by the way and what looks like a stock air filter. is your carb rejetted?

[@Maraggie]

Hi. The rule of thumb is that if you're only changing one part (exhaust or filter) you don't really need to rejet. The mixture screw on the carb should provide you with enough tweak to get the combustion right. If you're changing both the exhaust and filter (for K&N for example) then you will need to rejet indeed.

[@normanbuffett4642]

I see. When all three elements are replaced the increase in performance is amazing. Can you access the mixture screw without removing the carb?

[@Maraggie]

I'm sure it's more nippy but somehow I'm not that pushed to replace it all. I do have a mushroom air filter that will fit under the tank (nice clean look as a result) but that's on the shelf, waiting. I got a GPX750 chop project now and focusing on it. As for the mixture screw, it's a little fiddly and you need a long screwdriver but yes. Unless(!) the screw was never accessed before, then it will be covered up with a plug that you need to drill out. Mine was already open, thankfully.

[@naterobertson3366]

Love these videos brother!!! Extremely helpful!! Thanks for sharing your love and knowledge with us. Subbed and I'm working on a 2004 Suzuki Intruder 800cc Best Bike I've ever rode. Very reliable low maintenance and always a good time

[@xIKeroppi]

Hello did you ever have any starting problems? I have an 03 800 it cranks but wont turn off, this is my first bike

[@Maraggie]

Hi. Not really, no. Only when I ran out of fuel really. There can be many reasons for this. If I were you I'd check if you get spark at all first. If it's sparking, I'd look at fuelling then. I assume it was running ok but stopped? Was it after a long break from riding?

[@xIKeroppi]

@@Maraggie hey finally figured it out , one of my hoses weren’t plugged in thanks !

[@Maraggie]

@@xIKeroppi I'm glad it's sorted. Love an easy fix.

[@xIKeroppi]

Do you remember how tall your apes are?

[@Maraggie]

@@xIKeroppi I believe they were 16"

[@colbyrichter6472]

I have 2004 volusia were would I find longer cables

[@Maraggie]

Hi Colby. Usually ebay. Just search for "universal throttle cable kit" or brake/clutch kit. Go with decent brand, like Venhill or similar.

[@TITO0247]

IN MY 2003 VOLUSIA I START IT TODAY AND TURN ON LIKE EVER BUT THE STARTER KEEP ON, I TURN OFF THE SWITCH AND THE STARTER KEEP ON, I DISCONECT THE BATERY AND WAS OFF... DO YOU HAVE A TUTORIAL TO REPLACE THE STARTER ??

[@Maraggie]

Hi. That sounds like an issue with your starter button on handlebar. I would check this first as it sounds it's sticking. If it's not the button, then next in line is starter solenoid that needs checking.

[@TITO0247]

@@Maraggie HI THANKS FOR THE ADVISE, I CHECK THE HANDLEBAR START BOTTON AND IS FERFECT SO I CHE K ON THE SOLEINOID AND DONT WORK, I REPLACED IT AND IS WORK PERFECTLY NOW BUT... WHAT COUSE SOLEINOID WORKS BAD OR DAMAGE ? THANKS AGAIN !¡!

[@Maraggie]

@@TITO0247 Fantastic, I'm glad it's fixed. They go wrong sometimes, might be just the age.

[@cyasinko]

Is it possible to change bothe rims to 17 rims for front and rear

[@Maraggie]

Hi. I'm tempted to say that everything is possible but since I haven't tried it myself, I can't confirm. Sorry.

[@world-wide9136]

Hi buddy.. is this bike similar like the intruder 1500 ?

[@Maraggie]

Hi Will. Should be. It's just the bigger brother of VL800. I'm unable to confirm 100% as I never had 1500. Perhaps someone else will chip in to confirm.

[@philipbunney1895]

Hey maraggie my name is Phil Bunney I live in the US and would like to pick your brain a bit about doing an engine rebuild on a VL 800 if this message gets to you please reply with a way to contact you.

[@Maraggie]

Hello Phil. Thanks for reaching out. I'm always happy to help but in case of engine rebuild I haven't done one myself and I don't think I'd have a great deal of advice to give on the topic. If you still would like to reach out, you can find my email address in "About" section of my channel. All the best.

[@Obitron21]

dude!, you cant sell your volusia, then who will I go to for all the info I need for it......BTW just took my rear support struts off a while back you arent kidding about thread locker Ive got a picture of all those bolts blue threads all the way to the head I was about ready to scream lol

[@Maraggie]

+Ghost In The Machine Hey man, good to hear from you. Well time will tell what will happen. I just finished my painting workshop so I'm hoping to paint my bike this season. If it's cool looking it might be too hard to sell then haha. Good job on the bolts... they are a pain in the backside ;D

[@Obitron21]

+Maraggie oh, some words were said and this video alone gave me all the info I need to not buy the pro pipes lmao I had enough of an issue with the stock exhaust, and hopefully you dont sell it man Im never selling mine Im actually stead fast into rebuilding and customizing it to my liking problem is im the first one doing alot to it .....like everything is 2003 stock oh, and the fuel smell inside the stock air filter is both your pair valve, your aftermarket exhaust, and you (im guessing) unjetted carb the pair valve on aftermarket and even modified exhaust like mine is causes popping and backfiring being theres no longer that stock pressure, its main purpose is to pulse air into the exhaust to ignite any leftover fuel vapors ....which on your exhaust which looks massive might just cause a vacuum the bike is running pretty rich if there is a fuel smell in the filter, basic necessity for any exhaust replacement is a new filter and a stage 1 jet kit will be giving my bike those two improvements hopefully soon, while I dont smell fuel in the filter I do notice some heavy lag on a freshly warmed engine 2nd through low end of 4th gear if you do decide to remove the pair valve I'm warning you now you will hate the front cylinder pipe removal, took me thirty minutes a bolt to remove and twenty minutes a bolt to install seal.....it sucks going good though onto part 2 now

[@Maraggie]

+Ghost In The Machine Pro Pipe rocks...literally... I think neighbour's house shakes lol. The whole setup was running fine on Jardine Rumblers, with no/little backfiring (which I love anyway) which were very much straight through as well so I gave it all a go with ProPipe..but clearly it needs stage 1, which I might do as well soon. Depends on my son... 6y old and really liking the rides so might put stock back on so I can take him for trips without deafening him lol. Stock 2003 is a great place to start...ton of work though haha. Enjoy the vids...there's going to be about 8 in total I reckon.

[@Obitron21]

+Maraggie 6yr old huh, eh a little hearing damage is fine, rode on the back of my dads bikes all throughout the years and they were harleys but joking aside since I full hole saw drilled my pipes everyone on my street knows when I leave in the AM One of these days when I figure out a design I will be ordering a speedo plate from you though and if you head over to Volusiariders.com look at the custom mods sections and find my name to get a peek at my volusia enjoying the vids keep em coming

[@chrisreed7803]

I have an 04 vl800 that has a hard time shifting from 1st to 2and, it goes into neutral then I have to shift up a couple times to get into second, what could that be?

[@Maraggie]

Hi Chris. Are all other gear changes smooth?

[@chrisreed7803]

@@Maraggie they do, I found out the board was loose and caused the shift lever bolt to hit the cover, I fixed it. Thank you for the response

[@Maraggie]

@@chrisreed7803 Ah! We do like an easy fix. I'm glad it's sorted for you mate.

[@stormcaos]

can you please tell how to find the engine number?

[@Maraggie]

Hi. It should be on the crankcase, behind where you have the choke cable puller.

[@romapavlov4763]

Hi.I've got a problem.I want to change a choke cable as it's stack. But now I'm stack too as I have no idea how to do this. Please help ASAP. Thank You

[@Maraggie]

Hello Roma. There's no need to post the same question on many videos. I can see them all. Can you explain how it's stuck? Is it hard to move or doesn't move at all?

[@romapavlov4763]

@@Maraggie hi.Thanks for reply.Sorry for posting everywhere. It does not move at all.I get to the carb,undone 12mm nut,but the cable didn't come out.

[@romapavlov4763]

@@Maraggie tried wd40.No any difference.Pulled,shaked...No any difference

[@Maraggie]

@@romapavlov4763 Just to make sure we're talking about the same thing. You mean the starter plunger as shown on this photo? ibb.co/7CXvwTD I had that stuck on a different bike once and it was very heavy to remove. But that was on a bike that was stood for years and petrol built up and crystalised inside, making it difficult to take out. I got mine freed up by using penetrating oil and leaving it for few days soaking.

[@romapavlov4763]

@@Maraggie Yes it is that thing on the photo.Slight problem is,that I can use only this bike.And I need to use to get around. So You're saying that WD40(or similar) will do the "trick"? Another question.I think I damage the thread by tightening too much.Any idea?Does it must be tightened properly (when I fix it or if I fix it)or can be a bit loose?

[@leosig2849]

What bars?

[@Maraggie]

Hello mate. I'm afraid I cannot remember. They were off eBay I think. 16" I think.

[@jessejamesrice1]

How high are the handlebars?

[@Maraggie]

Hello mate. These are 16" narrow base ones.

[@jessejamesrice1]

Thank you mate, how tall are you and are they comfortable, what did you upgrade too? I have a 2001 and am 6'3 looking into VL1500 or HD street bob, thank you again.

[@Maraggie]

I'm 6'0 and they're very comfortable. Basic rules is that as long as you're not reaching higher than your shoulders, you'll be fine for long distances. Otherwise blood will drain and you'll get fatigue. Bike is also lowered by 2 inches at the back..makes it even easier to handle but I tend to scrape the floorboards on roundabouts ;) VL1500 or VN1500 will be sweet for you :]

[@jessejamesrice1]

Maraggie thank you mate, I have an offer on a Harley Davidson Street Bob from a friend of mine, took it for a spin and loved the feel. Forward controls and a bit more power. Thank you again man very helpful advice.

[@Maraggie]

Anytime :)