2004 Suzuki VL 800 Volusia - Answered Questions & Fixed issues

Free wiring diagram? At the library.

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my 2001 vl 800 speedometer will not work along with odemeter everthing else works but that<!-- from fixya rte -->

top of radiator fuel tank off cab top up reservoir behind bottom left hand side plastic cover

Is battery no use? so new battery after charging it.

It is a V-Twin so fires 1-2-1-2-1-2-1-2

Yes, completely normal. The choke is also known as an 'enrichment lever' and adds a bit of fuel to help cold engines start. When temperatures get up into the 80F range you may get away without choke, depends on how well your carbs are set up.

Dirty air filter is the most likely cause. Will your bike run leaner with air filter removed? DId you recently move to a different elevation? air fuel ratio needs adjustments in that case. Have you recently installed aftermarket intake or exhaust components? if so the air / fuel ratio adjustment is also required. To check for leaner running with air filter removed, you should buy some new spark plugs so you can see condition of plug correctly on the new plugs. First run the bike at 1/4 throttle for 15 minutes and remove plug and inspect. install new plug and repeat test for 1/2 throttle, 3/4 throttle, and full throttle, replacing the plug prior to each run. The throttle positions can be marked off with white tape and black tick-marks. you will put a white piece of tape on your rotating throttle with a single black tick mark and then you will take a second piece of tape on the stationary part of oyur handle bar and put a mark for 0 and full , then half, 1/4 and 3/4. these marks will help you maintain postion during the tests. The plug conditoin will reveal which fuel circuit you should address for your fouled plugs.

Hi, Have you checked and cleaned your spark plugs, remember it's usually the simplest thing that causes poor starting and or running issue's.

try new sparkplugs.drain carbis,to see what comes out.drain a bit of the fuel tank,to see what comes out.

I always go back to the basics. Fuels, spark, compression. Try a shot of starting fluid spray into the carb immediately hitting the starter, if it starts and dies the problem is fuel. If it doesn't even spit or try, it's ignition. Gasoline nowadays is poor, shelf life maybe 3 months. Use absolutely fresh non oxygenated (10% ethanol) premium. Spark plugs can fire out of the engine easier than when under compression. I use a dandy home made tester, a spark plug attached to a battery clamp which easily grounds to the engine. Use a healthy .050 gap to see the spark is strong enough to jump the distance. After you try to start it, pull your plug. Is it bone dry or wet? That'll give a clue. If all else fails it's time for a compression test, and determine if your spark is happening at the right moment. Re try your efforts first as described, get back to me with your results, and best of luck.

Before you remove the cable,zip tie the new one to the old one the full length of the cable,this will ensure the cable is routed correctly. If your bike has Mikuni carburration then this means that the end of the cable will have to be removed fromits plunger. This is done by unscrewing the black plastic 10mm nut at the carb and carefully unhook the cable end from the plunger,taking care not to lose the small cable spring.The leverend is self explanatory and very simple.

It;s normal, it keeps you safe and well and inside speed limits. Factory set, not adjustable.

Possible gas filter clog or pump not working two reasons 1 might not be getting eletricity to the pump or 2 fuel pump is burned out look at how old the vehicle is or milage

http://www.bikebandit.com/oem-parts/2004-suzuki-volusia-vl800-carburetor-model-k1-k2-k3-k4/o/m147645sch502866

under carriage,but if oil light not on, and your keeping up with maintenance, why worry?

water may be in spark plug cavity.

this sounds like a carby problem as it maybe the float sticking and over fueling ,have you noticed any fuel leeks ,this could just be a cable adjustment or idle speed adjustment ,it could be a blocked low speed jet in your carby ,try a few simple adjustments first if not it may be a job for your motorcycle dealer as they have the testing equipment ,hope this helps cheers pete

well a pump would have nothing to do with it but I fuel level sensor would... if it's a single wire sending unit you can test it with a dvom (digital volt ohm meter )

wrist pin , connecting rod, crankshaft bearings.

carb also has a phillips head drain screw facing the side on the bottom of the float bowl that will have to be drained if you suspect old or contaminated fuel. If bike sat too long a fuel system/ carb cleaning will be necessary.