Suzuki Intruder 800 cuts out completely (as in engine cut out) in 4th gear only. Change gears and it restarts the engine (if still rolling). Bike is also draining the battery.
Have you got a digital gear position clock on the bike
No gear position clock
try disconnecting the neutral sensor ,, does bike run in 5th gear
It runs in 5th. I just rebuilt the bike and this was the first time riding it. I got about 30km before it died. It was cutting in 4th from the get-go.
only wiring to gears is neutral sensor and oil pressure sensor. wondering if neutral sensor is faulty, normally this would hust cause a starting problem , unless the earth is bad/corroded and somehow crossing with an engine kill. be worth disconecting it and/or crossing it to see if problem improvesso wonder if something wrong there.
I think its the fuel pump. I have recharged the battery and now, when I try to start it, the fuel pump just vibrates and the starter motor does not run.
agree that needs sorting ,,, fingers crossed, come back if problem persists
Any idea how to test the fuel pump? mine has for wires(I only have directions for a fuel pump with 2 wires) Black/White, Black/Yellow, Orange/White, Yellow/Green.
this should helphttp://imageshack.us/f/214/pumpb.jpg/ brown black=black white
click on picture for clearer diagram
4. Connect jumper wires from a 12V battery to the fuel pump electrical connector as follows: a. Connect the battery positive (+) lead to the black/brown terminal. b. Connect the battery negative (-) lead to the black/white terminal. This is my problem, If the B/W is (-) then what is the (+)? By the way, thanx for all your help!!!
orange/white is to live and the other 2 wires are switch wires i.e. connect these to live too which will turn switch on
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SOURCE: battery location for a 2004 suzuki intruder 800
Hi ...... Find where the battery is, under the seat or behind a side panel. Disconnect the black (negative lead usually with a 10mm spanner then disconect the red (positive) lead. The battery will be held in place with a 'rubber' strap or a bracket and depending on type of battery there may be a vent hose from the battery to the lower half of the bike, this just pulls off and remains in place until you replace the battery. Installation is reverse except you connect red (positive) first.
Let us know how you get on.
SOURCE: Exhaust Pipes on 1995 Suzuki Intruder VS
Hi Lcyr.
Any changes you make to the exhaust system will alter the sound the bike produces. The more you cut baffles,and open up the exhaust, the louder it will get. What you do alter to a greater extent,is the state of tune of the motorcycle. Any changes to exhaust or inlet plumbing will require a retune of the engine to suit the modifications. This can be subtle to dramatic. Opening up exhausts can often rob low end power where exhaust port scavaging is relient on some back pressure for maximum effect.
Best to work directly with an engine tuner to do the mods that are known you can get away with, or buy aftermarket prebuilt pipes that have a known previously tested state of tune. Nothing worse than doing something, that then costs money to put back the way it was on finding out it didnt work as well as was hoped.. Hope this has helped you steer your custom mods a little. I can say with certainty, that I have ventured to do what you are doing many times in the past, and it has always cost me more money in tuning and... and well more parts :) Cheers
regards
robotek
SOURCE: 94 suzuki 800 intruder. clutch splips in
No adjusting is possible.
Slip can be caused by several defaults:
- Wrong engine oil ( SAE 10w-40 API SE or SF only )
- Weak clutch springs ( free spring length : 34mm ( 1.34in ) MINIMUM
- Worn clutch disk 2(internal teeths ) ( wear limit 3.15mm ( 0.124in ) ) This is the last disk, against the clutch center
- Worn clutch disks 1 (internal teeths) ( wear limit 2.62mm ( 0.103in ) )
- Clutch plates ( thikcness between 1.55 and 1.65mm / 0.0610 and 0.0649 inches
- Damaged pressure plate ( cracks round the spring holes )
To check the clutch parts, the right engine cover must be removed.
Take attention while loosening the clutch spring bolts!
Drain engine oil, and set engine into first gear ( this locks the clutch for an easy loosening of the spring bolts )
Hope it helps
SOURCE: battery removel for a 2004 suzuki 800 intruder
I know for the models till 2002 where the battery is located in front of the rear wheel.
Place the bike on her side stand
remove the negative battery lead at the left side, just below the transmission tube ( cone ) 10mm socket wrench
On the right side remove the security cap on the positive lead ( cross screwdriver ), then remove the positive lead.
The battery is hold in place with a 'floor plate'. remove both bolts of the floorplate ( on each side ) while holding the palte into place.
gently lower the plate and the battery.
I hope the 2004 model has the same assembly!
SOURCE: bike runs in neutral but cuts out when a gear is selected.
Your sidestand switch kills the engine if the bike is put in gear with the sidestand down. If your stand is up and this is happening either the switch is broken or out of position. If it is broken you can twist the wires together until you can replace the switch. If it is just bent out of position you can bend it back carefully.
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