20 Most Recent 2004 Suzuki VL 800 Volusia - Page 4 Questions & Answers

The speedo is rubber mounted so should not need tightening

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Bike-Doc

I HAVE A VL800 O5 K5 IF U CAN CONFIRM THAT THE MANUAIS THE SAME IWILL E-MAIL U ANY SECTIONS THAT U NEED.

Yes, right side of the axle.

remove the speedo display from t5he top of the tank. undo the bolts that hold the tank onto the frame.
there is a pushfit connection which is sort of mid tank area. this is one of these squeeze and push things.

Check your computer or your coil fuses to see if they were blown by the arcing.

check speed sensor if the output from it doesnt make it to the cluster no speed or distance change.

Check the leads to the posts. Even if they're slightly loose it can prevent the bike from getting enough juice. If they're good and tight try taking the battery to a shop and let them test for a bad cell

Turn off fuel tap ,disconnect fuel pipe from carbs .drauin fule using tank tap into container ,or remove thwe tank from the bike ,take care to remove all pipes connected to frame work .like overflow pipe / breather pipes etc etc .

the pass. seat has a bolt at the back side of it remove it now remove that seat. You can now remove the bolt for the driver seat. i also gave you the web site to world of power sports mircofishe for it
http://fiche.worldofpowersports.com/wps/Suzuki_OEM/SuzukiMC.asp?Type=13&A=253&B=49
Good luck be safe
Mark
C.C. Motorsports

The fuse box location is behind the tool box cover.

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Cheers.

I have speeds issue. The motor is not due to me, for it is on my friend. Only the gearbox is here. Newly a small gear had started to disengage from great Cam only when going by rise to slope. It does not expel bauds to even way

right above the kick stand is a inspection glass. bike must be level and not on kick stand when checking.

It sounds very much like the Speed Sensor has failed, it will need to be replaced. If this is not the problem then the Speedo itself could have failed but very unlikely.

whining noise from the motor at about 110 k's

Remove the choke cable and release it..pour in some WD-40 between inner and outer cable starting from any side making sure one end is facing down..at the same time holding the outer and you work with the inner moveing it until you see WD-40 coming out the other side of the cable.
Once the cable is out check the mechanism at the carburator if it works freely..it should do so.
Hope this helps!

you have a direct to ground short in the wiring for these two guages. You will need to trace the wiring back to see if you can locate any breaks or bare spots that would allow this ground short and repair

Check your speedometer gear box, it probably got bumped during removal/installation. The cable may have got pulled out. You can see the gearbox here: http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/45/Year/2004/ModelID/6619/Model/VL800Z_INTRUDER_VOLUSIA/GroupID/279409/Group/FRONT_WHEEL

Which one?
Here are links to fuel system and servicing for the VL800.
http://www.ioci.it/archivio%20tecnico/VL800/VL800_Fuel_Lubrification%201%C2%B0%20parte_134-150.pdf
http://www.ioci.it/archivio%20tecnico/VL800/VL800_Informazione%20tecniche_264-298.pdf

r/r the speedo head, most likely bad

peterbiltcoh,

If you haven't gotten an answer yet, here's how to check the coolant level in your '01 Volusia. The coolant tank is located on the bottom left side of the engine. There is a sight slot cut in the cover that will allow you to view the level. I preferr to take the cover off (3 screws) to make sure I'm seeing the marks on the coolant tank and to check the color of the coolant. It's an easy check even with taking the covers off (about 15 minutes). If the coolant is low, or discolored, you can make the necessary adjustments.