20 Most Recent 2004 Suzuki VZ 800 Marauder - Page 2 Questions & Answers

on most bikes it is on the right side of the frame directly under the handlebars.

Have a look at the side-stand micro switch, mounted on the frame, flush it out with WD40 or something similar ............ Let us know how you get on.

Suzuki prints a publication that cross references vin numbers to engine numbers. They are sent to dealers.

normal setting is achieved by turning the screws in till they stop then turn out 1 1/2 to 2 turns if you have 2 screws set the same start the bike and then adjust each screw in until you hear the rpms drop then turn out until you again hear the rpms drop the setting is 1/2 the number of turns beween in to die and out to die do the same with the second screw and alternate until you have both screws set in the middle you may have to adjust the idle setting as you do it as the fuel mixture will alter teh idle setting

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needle valve jammed open or dirt in it so its overflowing

The green connector is the ignition switch connector. By "wiggling" it you are bringing connection back to something in the area of that connector. Pay attention to all wires that may be moving during this process. There soldered wires on the back of the ignition switch itself that sometime break loose. Also loose battery cable bolts would cause this issue.

If it cuts out randomly I would suspect the green ignition wiring is where you need to start troubleshooting because the solenoid only starts the bike and a faulty one will not cut a running engine off, it just wouldn't start an engine. Check out all of your connections, breaking the connections at the connectors looking for corrosion or broken wires. Clean and put back together. Don't just spray with WD40 as that will do nothing. CLEAN CONNECTIONS are what you are after, not just damp free ones. Contact cleaner, soft wire brush, the wifes nail (emery) boards are the way to go. Pay particular attention around pinch points at the steering head as wires do not take kindly to rough play. Good luck.

Turn the idle screw to increase the idle speed. The bike should idle at 1000 to 1200 rpm when hot.

Bad spark plug wires

What year model and engine size marauder do you have. I am familiar with this model and may be able to answer your question

look at your library or at your dealer

There is a special tool to align the clutch while installing it. Hard to answer if people dont know what kind of vehicle u have!

If you have never done it before you will need a manual from a company such as Haynes or Clymer. This is mainly for the correct order in which to take the motor down, it will also tell you what to look for in the way of wear and what you will "Have" to replace for a rebuild. Difficulty is dependent on what your mechanical skill level is. I did my first engine at the age of 15, But I had a manual. Good luck.

You have a classic case of dirty contacts in your ignition switch. When your machine gets older dirt, grit, and bits of burnt copper tend to get smeared over the contact points inside your ignition switch. This shorts out the contact points or makes an electrical near impossible. Some switches are designed to have the contact base easily removed and replaced. Others you can carefully take apart. clean. and put back together. Worst case scenario you may have to buy a new switch (best option) or in the case of an older bike with discontinued parts then a used switch ( it could have the same problem your old switch has). To see a break down of parts available for your cycle, you can look at the parts microfiche at: bikebandit.com.

If you are still blowing fuses, keep looking for more bare spots in the wiring. Look under the tank.

You shouldn't need to size it, just find a site and enter your bike in. Take a look at this website
http://www.powersportsuperstore.com/Iron-Horse-MIDNIGHT-RIDER-TANK-PANEL-SUZUKI-800-VO-p/tr10-7868.htm