20 Most Recent 2002 Suzuki VS 800 Intruder Questions & Answers


It sounds like it may be!

2002 Suzuki VS... | Answered on Aug 29, 2019


Hi, Anonymous, a proper clutch adjustment starts by squirting some silicone spray or Brake Kleen into the top of the rubber boot on the clutch cable and sliding it back exposing the cable adjuster. Loosen the jam nut and turn the adjusting screw all the way in. Loosen the jam nut on the clutch pack adjusting screw until light resistance is felt against the clutch rod then back the adjusting screw out 3/4 of a turn and tighten the jam nut. Go back to the clutch cable adjuster and back it out until there is 1/8" free play between the clutch lever and the bracket perch. This is correctly accomplished by pulling the clutch cable end outward with your right hand and pulling the clutch lever in with your left hand and modest pressure on both hands to eyeball the free play. Tighten cable adjuster jam nut and slide rubber boot back to its original position.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
How To Adjust Clutch Lever Free Play And Why Its Important MC Garage
https://www.dailymotion.com/video/x36vbtq
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 12, 2019


Hi, Reta and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Faulty main circuit breaker and or connections.
4. Faulty ignition coil and or connections.
5. Faulty spark plug, oil or gas fouled, wrong heat range or service type, wrong gap, loose in the cylinder head, broken electrode or insulator.
6. Faulty spark plug cables, leaking or broken, internal damage check for spark leakage in the dark.
7. Faulty ignition module, switch, CKP, MAP, CMP, sensor and or any connector in the ignition circuit could have corroded, loose, or broken pins/sockets
8. Burnt exhaust valve or air leak in the exhaust system.
9. Improper valve clearance (too tight).
10. Check for generated diagnostic codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Front Cylinder misfires Rough Idle sputters and dies Suzuki Volusia Forums...
Bike is sputtering at low throttle Would like your thoughts assistance...
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Jrkaeff123 and the usual suspects are:
1. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, stator, magneto, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Faulty neutral, side stand or clutch lever safety switch.
10. Faulty or corroded kill switch.
11. Accelerator pump damaged or not working.
12. Water or dirt in the fuel system, carburetor or filter.
13. Restricted, blocked or kinked fuel line.
14. Fuel tank empty.
15. The gas cap is not venting properly or fuel tank venting system blocked, loosen gas cap and go for a test ride.
16. A failed fuel pump, pressure regulator and or fuel injectors.
17. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
18. Needle and seat stuck closed in the float bowl.
19. Petcock clogged or damaged.
20. Lean angle switch is faulty or needs adjustment.
21. Catastrophic engine failure, perform a compression test.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
MY BIKE JUST STOPPED RUNNING WHILE WAS RIDING
Intruders Alert
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Jrkaeff123 and the usual suspects are:
1. Fouled spark plug.
2. Fuel injector stuck open.
3. Carburetor float needle valve, not seating.
4. Carburetor float stuck open.
5. Exhaust valve stuck open.
6. Exhaust valve bent.
7. Fuel valve leaking back through the vacuum line.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Oil Gas Spitting Out Of The Exhaust Sportbikes net
http://cruiser.mototribe.com/discuss/gas-leaking-out-exhaust-header-suzuki-vl1500-2004
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=2002+Suzuki+VS+800+Intruder+fuse+box+location&tbm=isch&source=univ&sa=X&ved=2ahUKEwj3r9zz8PrgAhUEtlkKHTP7DugQsAR6BAgEEAE&biw=1440&bih=757
Suzuki VL800 C50 Main 30 Amp Fuse Box Location
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=2002+Suzuki+VS+800+Intruder+wiring+diagram&tbm=isch&source=univ&sa=X&ved=2ahUKEwiTpauX8PrgAhUstlkKHZbuDawQsAR6BAgAEAE&biw=1440&bih=757
Suzuki Motorcycle Wiring Diagrams
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Anonymous you need to make sure you have no intake leaks by spraying some Brake Kleen, Contact Cleaner, Starting Fluid etc. around the intake manifold and seals, if the RPM's go up or down significantly then you have a leak that needs to be fixed before you can continue with the carburetor adjustment.
The engine should be at operating temperature with the choke off to set the idle between 950-1050 rpm. Turn the idle skrew clockwise to increase the idle speed and counterclockwise to decrease the idle speed. If you have access to your air-fuel mixture skrew you may turn it as well, if not there is a video below on how to gain access, make sure you start with clean or new spark plugs. Gently turn the air-fuel mixture skrew clockwise until it starts to bottom out "STOP" do not over tighten as it will damage the taper on the end, now back the skrew out 1-1/2 full turns to establish a starting point start the engine and check the idle rpm's and turn the idle skrew accordingly for 950-1050 rpm if necessary, turn the air-fuel mixture skrew 1/4 turn at a time and let the engine settle for about 10 seconds, turn the skrew clockwise for a leaner mixture and counterclockwise for a richer mixture, you are seeking the highest rpm your air-fuel mixture skrew can acquire without going past 3 full turns from the bottom then resetting the idle skrew back down to 950-1050 rpm If you can not detect any rpm change and can not stall the engine by turning the air-fuel mixture skrew all the way in then your pilot/low-speed jet is too big and needs to be replaced with the next size smaller. Final adjustment should be made with a clean air filter mounted to the carburetor.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://www.intruders-alert.com/viewtopic.php?t=4001
https://www.youtube.com/watch?v=DyiIiIuF05I
https://www.manualslib.com/manual/816746/Suzuki-Vs700-1985.html#product-Intruder%20VS
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere $15 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.google.com/search?q=2002+Suzuki+VS+800+Intruder+fuse+box+location&tbm=isch&source=univ&sa=X&ved=2ahUKEwicwInUgfrgAhUFuVkKHRujCE4QsAR6BAgEEAE&biw=1440&bih=757
Suzuki Boulevard C50 Fuse Location
https://www.tradebit.com/filedetail.php/279276286-suzuki-vs700-vs750-vs800-1987-2009-service-repair $15
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

2002 Suzuki VS... | Answered on Mar 11, 2019


Hi, Anonymous before testing any electrical component in the Starting Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Engine Run Switch is "FAULTY" or corroded.
4. Check the battery terminals for damage or corrosion check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter.
5. Bank angle sensor needs a reset or is faulty.
6. FOB battery low or dead.
7. Faulty ignition switch.
8. Faulty starter button.
9. Faulty kickstand, clutch, neutral safety switch.
10. Security alarm needs a reset.
11. Starter relay, solenoid, starter motor or circuit wiring faulty.
12. Starter armature or field coils have failed.
13. Main fuse or circuit breaker may be blown or faulty.
14. Faulty ignition relay.
15. The electric starter is working but starter clutch has failed.
16. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Intruders Alert
https://www.motorcyclecruiser.com/g00/what-to-do-if-your-motorcycle-doesnt-start?i10c.ua=1&i10c.encReferrer=&i10c.dv=21
Suzuki VL800 Service Manual
https://www.partsfish.com/oem-parts-for-suzuki
Suzuki VL800 Owner Manual

2002 Suzuki VS... | Answered on Mar 07, 2019


Hi, Gail the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Suzuki VL800 Owner Manual
https://www.partsfish.com/oem-parts-for-suzuki
Suzuki VS700 Service Manual
https://www.motorcyclespecs.co.za/model/suzu/suzuki_vs800gl_intruder%2093.htm
Suzuki Intruder

2002 Suzuki VS... | Answered on Feb 18, 2019


Hi, Deana what you are missing is the ability to properly track down a simple wiring issue so get out your test light, read the wiring diagram provided and track down the open-short-ground and the usual suspects are:
1. Bulbs are burnt out.
2. Light circuit fuse was blown.
3. Faulty ignition switch.
4. Faulty, corroded or cut wire connector, pins, sockets etc. in the running light circuit.
5. Loose, broken or corroded common ground.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
2002 Suzuki VS 800 Intruder wiring diagram Google Search
Suzuki Motorcycle Wiring Diagrams
Volusia 2002 vl800 taillights running lights not working Suzuki Volusia...
Suzuki VL800 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki VL800 Owner Manual

2002 Suzuki VS... | Answered on Sep 22, 2018


Hi, Elwood and the usual suspects are:
1. Fouled spark plugs.
2. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
3. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Open-short-ground in the wiring between the alternator to the ignition module/CDI box to the ignition coil.
5. Faulty pins or sockets in the plug connectors.
6. Spark plug cables in bad condition, shorting/leaking, spark plug cable connections loose check for spark leakage in the dark.
7. Faulty ignition coil or electronic control module/CDI box.
8. Faulty pulse coil.
9. Faulty CKP, CMP, or BAS sensor.
10. Faulty ignition switch.
11. Faulty run/off switch
12. Tilt sensor needs a reset.
13. Security alarm failing to disarm needs reset
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Headlight works starter turns over no spark RE Fixed Suzuki Volusia Forums...
How to diagnose no spark situation on motorcycle
Suzuki VL800 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki VL800 Owner Manual

2002 Suzuki VS... | Answered on Sep 12, 2018


could be a Vacuum hose or could be dirty carb jets.

2002 Suzuki VS... | Answered on Nov 21, 2017


Hi Chermassey1, and the usual suspects are:
1. Throttle cables misaligned or misrouted (may also affect idle speed).
2. Damaged or restricted fuel tank venting system.
3. Inlet system air leak.
4. Vacuum piston malfunction.
5. Accelerator pump leaking or no output.
6. Plugged bowl vent.
7. Fuel level in bowl too low.
8. Restricted fuel supply passages.
9. Plugged jets or passages.
10. Worn or damaged needle or needle jet.
12. Enrichner valve not seated or leaking.
For more information about your issue please visit the websites below and for specific information or questions you can reach me at xlch@mail.com. Good luck and have a nice day.
2002 Suzuki Motorcycle Service Repair Workshop Manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2002 Suzuki VS... | Answered on Sep 27, 2015


When you drove it for 10 minutes did it work & run perfect without any missing? One cylinder possibly started missing backfired and then maybe the carb flooded some how. I would pull both plugs first. Have a look at the plugs, then you will be able to tell which one was missing (wet with fuel). Check compression on each cylinder and then check the carb. I hope this helps.

2002 Suzuki VS... | Answered on Jul 11, 2015


Hi, it all depends on the type of riding you do. Mr Suzuki advises 4,000 miles between oil changes. This is OK if you do a lot of miles every time you ride. If you do a lot of short journey's then you need to to do more frequent oil changes. I normally do an oil change every 2,000 to 2,500 miles as I do a lot of short trips. One of my bikes has no cam shaft bearings and I do an oil change every 1,000 to 1,500 miles regardless.

Hope this helps.

2002 Suzuki VS... | Answered on Apr 06, 2015


It can use either. What ever you decide, keep the same decision every time you change oil in the future.

2002 Suzuki VS... | Answered on Apr 01, 2015

Not finding what you are looking for?
2002 Suzuki VS 800 Intruder Logo

65 questions posted

Ask a Question

Usually answered in minutes!

Top Suzuki Experts

Marvin
Marvin

Level 3 Expert

85178 Answers

Arnie Burke
Arnie Burke

Level 3 Expert

5944 Answers

ROB

Level 3 Expert

858 Answers

Are you a Suzuki Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

View Most Popular

VS 800 Intruder Suzuki

  • VS 800 Intruder Suzuki

Most Popular Question

after changing spark plugs riding bike

  • Motorcycles
Loading...