Injector Advice Needed - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 8 (permalink) Old 03-27-2019, 08:49 PM Thread Starter
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Injector Advice Needed

A while back, my bike was running crappily. It was missing and backfiring on deceleration. A little detective work revealed a fouled plug on my front cylinder. I suspected an injector was stuck open & spraying too much gas. Luckily I happened to have a complete spare throttle body around, so I swapped it in, and my problem instantly disappeared.

Fast forward a few months, and I have the same symptoms beginning to appear. I can also smell unburned fuel when I'm sitting at a red light. It runs pretty well at 60 mph, though, so my theory is that I'm getting too much fuel at lower rpms, but when I open it up on the highway, the extra air puts the air/fuel ratio much closer to the right mix. It's not missing or backfiring at highway speed, which points me away from it being an electrical problem. I'm not getting any warning lights on the dash. Everything stock - no power chip or anything.

I suspect a bad injector again. I'm going to take a look at the plugs this weekend and that should tell me which cylinder it is. (I'm already de-paired, and I've checked for obvious things like a disconnected hose causing a vacuum leak or an unplugged sensor.) I'm leaning toward just buying a brand new injector to swap in, which is kind of pricey. My question is, if you have an injector that's staying open and spraying too much fuel, has anyone had any luck having it cleaned, or is that mainly for a clogged injector? I'm trying to decide whether to spring for a brand new injector, or to save a few bucks and try to get my old ones working right. I don't want to get an injector serviced and have it flow great on the bench, but stay open and flow too much when back on the bike. Curious to hear what y'all think.
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post #2 of 8 (permalink) Old 03-28-2019, 07:23 AM
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From another thread on Injectors:

I got on Rockauto and looked up injectors for that car, ordered a pair of Autoline 16323 remans (which cross references to the Honda part mentioned earlier). The picture with it shows it's the same injector with a clearly visible "C" on the side. They're $22/ea, and you can order them individually so just got two.

The OP claims them to be the same as the Suzuki OEM. No idea if that is the case or what, but for $22 each, it is worth the effort in my opinion

One thing you may want to do is a compression check, because your symptom sounds an awful lot like what I experienced with my bike. Front cylinder went, ran like crap at idle and smelled like gas when at a light. It went away on the highway too.
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post #3 of 8 (permalink) Old 03-28-2019, 09:05 PM Thread Starter
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Thx - symptoms showed up suspiciously right after I did a valve adjustment so I'm going to recheck that too. I've done it many times in the past without screwing up, but there's always a first time, I guess. I do have a compression gauge from the last time I had this same problem.
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post #4 of 8 (permalink) Old 03-29-2019, 10:58 AM Thread Starter
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I checked out that other thread and saw the OP gave up on the Honda injectors and ended up buying a throttle body from ebay. I could go that route, but I hate taking a chance on a part that could have the same problem that I have. What I'm gonna do this weekend is redo my valve adjustment carefully and check my plugs (the spark plugs will tell the story). If my theory is correct, I have 1 good injector in the throttle body on the bike, and 1 good injector in the throttle body on my workbench, so for zero dollars I can at least get the two good injectors into the same throttle body on the bike. If it works, problem solved. If it doesn't, it gives me more info to try to narrow the problem down further.
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post #5 of 8 (permalink) Old 03-29-2019, 11:31 AM
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The problem in my case ultimately was a bad fuel pressure regulator. I did buy a complete intake manifold, but literally never even took it out of the box. I stuck it back on ebay and someone bought it almost immediately. I also bought a complete in-tank assembly (it was off a later year C50, so the connector was different, but I poached the fuel filter and regulator off it which swapped right into the pump assembly on my '05. It's been running flawlessly since (on it's original injectors that I ultrasonic cleaned). Unfortunately I can't really confirm/deny if the Honda injectors would work, since I tested them with (I didn't realize at the time) low fuel pressure. I ended up returning all of them.

You can try cleaning the injectors. Harbor Freight sells a sonic cleaner for about $70 with a coupon. For a cheaper route, I also have a couple injector cleaner adapters I got off ebay- cheap- it's just an adapter that goes on the top of a can of carb cleaner, and you stuff the injector in the other end. Has connectors you can hook up to a battery to open the injector, then you just shove the whole thing down and it blasts carb cleaner through the injector. Think the kit was like $10, certainly worth a shot. If you suspect one is bad/leaking, this is also easy enough to test, pull it out of the bike and put pressure air behind it. Any air leaking out the nozzle will be a giveaway.
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post #6 of 8 (permalink) Old 03-29-2019, 08:21 PM Thread Starter
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The plot thickens. I stripped the bike tonight to get it ready for a valve adjustment do-over, and when I pulled the plugs, the front one appeared to have zero gap. The feeler gauge says there's a gap of 0.008, but you really have to hold it up to the light bulb to see light through the crack. Well, that could sure make the bike run poorly on one cylinder. I can't explain why on earth the gap would be like that ... well, I can explain it if there was interference between the top of the piston and the ground electrode ... but there's no other indication of a bad bearing. I'm going to put new plugs in it and turn the engine over without the plug wires connected to see if I hear anything, and hope for the best. Anybody know if they make a plug that's just a hair shorter in length from the crush washer to the ground electrode?
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post #7 of 8 (permalink) Old 03-31-2019, 12:46 PM Thread Starter
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Problem solved: it was the improper plug gap. Put it back together & rode 50 miles with no further problems. Thinking back, I did have some trouble getting the old plug in, and it kind of wedged itself into the recess - I must have closed the gap when I was fishing it out of there. I really lucked out.
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post #8 of 8 (permalink) Old 03-31-2019, 02:32 PM
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Glad it was something simple. Keep us informed as to how it does.

I can head East or West, it doesn't matter as long as it's on 2 wheels.
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