First Carb rebuild on my 03 Vol - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
LinkBack Thread Tools
post #1 of 7 (permalink) Old 08-19-2012, 05:29 PM Thread Starter
Senior VR Member
grunt69's Avatar
Join Date: Aug 2007
Location: Fair Oaks Ranch Texas
Posts: 2,269
Thanks: 389
Thanked 530 Times in 256 Posts
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.
grunt69 is offline  
Sponsored Links
post #2 of 7 (permalink) Old 08-19-2012, 07:21 PM
Senior VR Member
03volusiarider's Avatar
Join Date: Aug 2010
Location: Duffield,VA
Posts: 3,872
Thanks: 250
Thanked 725 Times in 647 Posts
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.

03volusiarider is offline  
The Following User Says Thank You to 03volusiarider For This Useful Post:
grunt69 (08-19-2012)
post #3 of 7 (permalink) Old 08-19-2012, 08:32 PM
Senior VR Member
Join Date: Jun 2012
Location: Buford, GA
Posts: 484
Thanks: 0
Thanked 160 Times in 115 Posts
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.

DrBob is offline  
The Following User Says Thank You to DrBob For This Useful Post:
grunt69 (08-19-2012)
post #4 of 7 (permalink) Old 08-19-2012, 08:53 PM
Senior VR Member
BIGBIRD123's Avatar
Join Date: Jul 2011
Location: Great State of Texas...where else?
Posts: 2,395
Thanks: 532
Thanked 424 Times in 289 Posts
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...

2005 C50 R.I.P.
2006 Street Glide...Screaming Eagle 95" Stage 1 with V&H Bigshot DualsR.I.P.
2007 HD Ultra Classic Named "The 8lack 8itch"...96" Screaming Eagle 255 Cams, Stage 2, 14" Apes
BIGBIRD123 is offline  
post #5 of 7 (permalink) Old 08-20-2012, 02:40 AM
VR Member
Join Date: Jul 2012
Location: Eastern Washington/ Northern Idaho
Posts: 104
Thanks: 8
Thanked 13 Times in 9 Posts
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!
Cooteboy is offline  
post #6 of 7 (permalink) Old 08-20-2012, 09:20 AM
Senior VR Member
shortfoot's Avatar
Join Date: Sep 2011
Location: Pacific North Wet (shelton,Wa.)
Posts: 707
Thanks: 290
Thanked 107 Times in 94 Posts
I would go back inside and check the valves for being too tight !

VR Wescalero Member Shortfoot
shortfoot is offline  
post #7 of 7 (permalink) Old 08-20-2012, 11:29 AM
VR Member
Join Date: Feb 2012
Location: San Antonio, TX
Posts: 99
Thanks: 3
Thanked 18 Times in 14 Posts
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
88CougarGT is offline  
The Following User Says Thank You to 88CougarGT For This Useful Post:
grunt69 (08-20-2012)
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome