2004 Suzuki VL 800 Volusia - Page 8 - Answered Questions & Fixed issues

Take it to your Suzuki dealership for new components to be fitted. Most drivers are insured for theft, so the cost should be covered.

Are there any other light on the dash display? FI refers to the Fuel Injection system. If it is on and staying on it is possibly an electronics fault detected by the ECU, (Electronics Control Unit). You should get a good mechanic to look at this as they will have the correct diagnostic tools.

If the spark plugs are black, it is running rich, end of story, you are dumping too much fuel. You need someone that can do carb tuning on the bike. There is help in the Volusia Forums and it appears to be a known issue.. https://www.google.com/search?q=2004+Suzuki+Intruder+VL1500+running+rich ..

is it a diesel or petrol ?

Fuel starvation will do that. Check the fuel filter.

ck this site.... https://www.thumpertalk.com/forums/topic/1091357-two-stroke-transmission-oil/

Depends on the time it takes them and their hourly rate. I would pose the question to a Suzuki dealership.

More information please. What EXACTLY is it doing? Slack clutch lever? Stuck clutch lever? Crunching or grinding as you try to shift? Grabbing and stalling as it selects the gear? Start at the clutch lever. Check it is pulling the cable then check at the transmission end that the cable is connected and moving with the lever. Next check the lever on the actual transmission. Does it seem too tight or too slack? These will give clues as to where the issue could be. It's a 37 year old bike so is it the original Clutch? Even motorcycle clutches wear out.

The specific steps for accessing the one-way Sprague for the starter in your engine's crankcase cover may vary depending on the make and model of your engine. However, here are some general guidelines:

1. Refer to the engine manual: The first step is to consult the manual for your engine. This will provide you with specific instructions for accessing the crankcase cover and the one-way Sprague.
2. Disconnect the battery: Before working on your engine, always disconnect the battery to prevent accidental electrical shock.
3. Drain the oil: Depending on the engine, you may need to drain the oil from the crankcase before removing the cover. Make sure to have a container to collect the oil.
4. Remove the bolts: Once the oil is drained, remove the bolts that secure the crankcase cover. You may need a socket wrench or other tools to do this.
5. Gently pry off the cover: Use a flathead screwdriver or a plastic pry tool to gently pry off the cover. Be careful not to damage the gasket or any other components.
6. Access the one-way Sprague: With the cover removed, you should be able to access the one-way Sprague. Depending on the engine, you may need to remove other components to get to it.
7. Inspect the one-way Sprague: Once you have access to the one-way Sprague, inspect it for any signs of wear or damage. If necessary, replace it with a new one.
8. Reassemble the engine: Once you have completed the repairs or maintenance, reassemble the engine by following the reverse steps.
9. Refill the oil: Refill the crankcase with the appropriate amount and type of oil.

Remember to always consult the manual for your engine and to take appropriate safety precautions when working on your engine

Unfortunately, I couldn't find a color code diagram for the ignition switch of a GZ250 Suzuki motorcycle. However, the ignition switch usually has the following wires:

1. Red wire: This is the main power supply wire that connects to the battery or the fuse box.
2. Black wire: This wire is usually connected to the ground or the frame of the motorcycle.
3. Brown wire: This wire is connected to the starter solenoid or the starter button.
4. Yellow wire: This wire is connected to the lighting system, such as the headlight, turn signals, and brake lights.
5. Blue wire: This wire is connected to the ignition system, which includes the spark plugs, coils, and other ignition components.

It's important to note that the color coding may vary depending on the model and year of the motorcycle. If you need further assistance, I recommend consulting a Suzuki dealer or a certified motorcycle mechanic. They will have the knowledge and experience to help you with your specific motorcycle model.

turn headlights on, measure voltage, if they don't come on the battery is bad

Here is a general fuel line diagram for a 1990 Suzuki RF 600 Katana:

1. Fuel tank: The fuel tank holds the gasoline and is typically located on top of the motorcycle frame.
2. Fuel petcock: The fuel petcock is a valve located on the bottom of the fuel tank that controls the flow of gasoline to the engine.
3. Fuel filter: The fuel filter is located between the fuel tank and the carburetors and helps to remove impurities from the gasoline.
4. Fuel lines: The fuel lines connect the fuel tank, petcock, fuel filter, and carburetors together in a specific sequence.
5. Carburetors: The carburetors mix the gasoline with air and deliver the mixture to the engine cylinders for combustion.

The exact fuel line routing and connections may vary depending on the specific model and year of the Suzuki RF 600 Katana, so it is important to refer to the owner's manual or a detailed service manual for accurate information. Additionally, any modifications or repairs to the fuel system should be done by a qualified technician to avoid damage to the motorcycle or injury to the rider.

The rectifier on a 2001 Suzuki Intruder 800 is typically located near the battery, under the seat. It is usually attached to a bracket or secured with screws to the motorcycle's frame. To locate the rectifier, you may need to remove the seat and possibly the side panels. Once you have access to the battery, follow the wires that are connected to it. The rectifier should be mounted nearby and have wires connected to it as well. If you're having trouble locating the rectifier or need further assistance, I would recommend referring to the motorcycle's owner's manual or consulting with a qualified motorcycle mechanic.

Yes, you will need to split the casing in order to replace the kick start shaft. The exact details of the process vary depending on the model of your dirt bike, but it will likely involve draining the engine oil, removing the side cover and clutch, and then removing the kick start shaft. Once the shaft is out, you can replace it with the new one and reassemble the engine.

Check your clutch lever switch, check to see if both wires are still connected. If they are, press and hold the starter. button.

Installing an aftermarket fuse block on a 1984 Suzuki GS550L can help protect your electrical components from damage due to power surges and short circuits. Here are the steps to wire an aftermarket fuse block on your bike: Materials:

• Aftermarket fuse block
• 10 gauge wire
• Wire cutters/strippers
• Crimping tool
• Ring terminals
• Zip ties
• Electrical tape

Instructions:

1. Locate a suitable location for the fuse block on your bike, such as under the seat or on the frame.
2. Disconnect the battery to avoid any accidental electrical discharge.
3. Determine the total electrical load that will be connected to the fuse block and choose a fuse that is appropriate for the total amperage required.
4. Use the wire cutters to cut the 10 gauge wire to the desired length for each circuit, leaving extra slack for any bends or turns.
5. Strip the ends of each wire using wire strippers, exposing about 1/4 inch of bare wire on each end.
6. Attach one end of each wire to a ring terminal using a crimping tool.
7. Connect the ring terminals to the appropriate circuits on the fuse block, following the manufacturer's instructions.
8. Secure the wires and fuse block to the bike frame using zip ties, ensuring that they are not interfering with any moving parts or causing any obstruction.
9. Reconnect the battery and test the circuits to ensure proper functioning.
10. Finally, wrap the exposed wire connections with electrical tape for added protection.

Remember to double-check all connections and ensure that the fuse block is properly installed and grounded to avoid any electrical issues. It is also recommended to consult a professional if you are unsure about any of the steps.