First Carb rebuild on my 03 Vol - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum

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Old 08-19-2012, 05:29 PM   #1 (permalink)
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Default First Carb rebuild on my 03 Vol

So Steve and I rode the hill country last Sunday and I had no upper end above 70, poor throttle response, and a misfire/ drop in rpms at the 65 - 70 range. Started, idled, and low end were good.
We had adjusted the valves and changed to plugs so we knew we were good there.
The manual puts all the symptoms in either clogged main, clogged jets, or clogged float. The secondary pronblems are vacuum lines and air leaks at the collar.
So we are going to rebuild the carb on Tuesday. Question is : Do they[suzuki] have a "carb kit" that has all the gaskets, o rings, etc or do you have to buy them seperatley? Q2: Anything out of the ordinary that we should look for?
The manual seems to be pretty straightforward as far as the rebuild goes.
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Old 08-19-2012, 07:21 PM   #2 (permalink)
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You really dont need a Carb kit, as there is nothing in there that can really go bad. Just take it apart and make sure all the jets are clean and clear and put it back together.
If it ran good before the valve adjust, i would suspect something there first.
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Old 08-19-2012, 08:32 PM   #3 (permalink)
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Yeah, if it ran fine before you adjusted the valves and changed the plugs, and it runs poorly after you adjusted the valves and changed the plugs, that does not lead me to conclude that that problem is that the carb needs rebuilding.

Those symptoms could be caused by the valves being too tight, or from something not being connected when you put everything back together. Check and make sure all the hoses are where they should be, and that the tube between the air box and carb is tight at both ends. If everything is as it should be, start with some spray carb cleaner and some 'in the tank' cleaner like seafoam or gumout.
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Old 08-19-2012, 08:53 PM   #4 (permalink)
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we have been using Seafoam but the valves before the valve job had NO gap...and it ran alright but wouldn't idle for crap...
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Old 08-20-2012, 02:40 AM   #5 (permalink)
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I haven't checked on any Suzuki sites, but Keyster has been around forever. I found these kits off of eBay the other day - contemplating getting my own.

SUZUKI VL800 INTRUDER CARB KIT 2001 - 2005 | eBay

They're a fair price too!
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Old 08-20-2012, 09:20 AM   #6 (permalink)
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I would go back inside and check the valves for being too tight !
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Old 08-20-2012, 11:29 AM   #7 (permalink)
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Whenever I build a carb, I let it soak disassembled in carb dip for about a week. I would check your valves like the others suggest.
Pull the plugs and read them. I would also double check the carb boots to see if any are loose and you have a small vac leak.

If you are bound and determined, take the carb back apart, here is my method:
(Note that I've never done a vol carb, but it has worked well on holleys, and my GS550s carbs I've done)

Disassemble, remove jets and let it soak. Then blow through all the passages with spray carb cleaner. Pay special attention to the little holes near where the throttle plate closes. Make sure you find where to spray to make carb cleaner come out of those holes. They are your idle and transition jets and most likely to get clogged.

Take a brass wire brush and pull one of the wires out and stab it into the butt end of a match stick. Use it to clean the jets. Scrub them good n clean.

Put the float needle in, hook a piece of hose to the fuel line and give a gentile blow. If it leaks, then you need to repair or replace the seat.

Install the float. Set the height. Set the height again. Check the height. Then set the height again.

Finish re-assembling and button up the carb. Spend alot of time checking for vacuum leaks. Double check all boots.

I think there is only one carb on a VOL so there should be no need to sync them. (This is a major pita on a quad carb setup).

Here is a link:
How to Clean a Motorcycle Carburetor, the RIGHT way. Evan Fell Motorcycle Works

-Hope some of this helps
-DZ
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