Fuel issue? - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 10 (permalink) Old 08-03-2019, 03:37 PM Thread Starter
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Fuel issue?

Okay new member here. I have a 2005 Suzuki boulevard 800. I bought the bike two weeks ago. The guy I bought it from let it sit for about a year and the fuel pump locked up on it. He put an aftermarket pump on and it ran fine. Two days after I bought it, I drove to a gas station. Shut the bike off, went in and bought a drink, cane right back out. When I started the bike, it was running different. Went to take off and had no power it just kept stalling. I had to open the throttle wide open to take off and had nearly no throttle response. I was able to drive home but had to keep the throttle open when slowing down or at red lights to keep from stalling. Next day I took the tank off and tested the fuel pump. Only 10psi when the pump was in the tank but when I took the pump off the assembly I had over 50psi. I narrowed it down to the pressure regulator which was just blowing fuel out of the diaphragm. I wanted to make sure that was it so I rigged the regulator so that it couldn’t blow the fuel out. The bike ran perfect. So I ordered a brand new assembly. New pump,filters,regulator, whole 9 yards. When I put the new assembly in the tank and started the bike, had the same issues. No power, no throttle response and stalling. Can anyone offer any insight to what may be going on here?
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post #2 of 10 (permalink) Old 08-03-2019, 04:57 PM
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If he let it sit for a year while empty, there may have been rust in the tank. Some may have gotten to the injectors and clogged them.
I'm no mechanic, but it seems logical.

I can head East or West, it doesn't matter as long as it's on 2 wheels.
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post #3 of 10 (permalink) Old 08-03-2019, 05:17 PM Thread Starter
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See I thought about that also. So I took both injectors off and cleaned them. I put alligator clips on the terminals so I could open the injectors and sprayed carb cleaner through them both. Both had good flow and spray pattern.
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post #4 of 10 (permalink) Old 08-03-2019, 05:21 PM
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But how did the inside of the tank look when you put the new pump in?

I can head East or West, it doesn't matter as long as it's on 2 wheels.
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post #5 of 10 (permalink) Old 08-03-2019, 06:56 PM Thread Starter
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The inside of the tank had some surface rust. Maybe some of that came off and worked it’s way down to the injectors.
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post #6 of 10 (permalink) Old 08-05-2019, 08:01 PM
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I ran into essentially the exact same problem you described on the exact same bike. The fuel pressure regulator lasted about a week after "reviving" the bike from sitting for years and then one day it just started running like complete crap, and it ended up being fuel was gushing out of the regulator's diaphragm and there was only like 15psi at the outlet. The bike would start but ran awful, exactly like you described. Very low power, stalling at idle, ect.

I ended up getting a complete used assembly (off a later model, so it had extra wiring for the gas gauge and stuff, but the rest was identical) off ebay and poaching the regulator off it since Suzuki does not sell just that part. I did find a company called HighFlow Fuel Systems, who sells aftermarket fuel pumps, sells replacement regulators for other Suzuki models that look similar (listed as for SVs and V stroms) that I strongly suspect could be adapted to work for the C50 by modifying the clip that holds it in place slightly.

The original filter was also totally blown out/rusted and I think was also contribuiting to clogging the injectors, so I swapped that with the newer one also. While it was apart I tossed the injectors in a ultrasonic cleaner and then blew them out with carb spray. Put it back together and the bike ran like new and has been for several thousand miles now.

Have you tested the new assembly to ensure you're getting ~45psi out the outlet? I mean you'd like to think it's ruled out being all new, but if you have the same symptoms, could very well be the same problem as before (low fuel pressure). Both MAP sensors hooked up? Easy to miss one of the hoses, and if left off will cause a massive vacuum leak and the bike will barely run.
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post #7 of 10 (permalink) Old 08-07-2019, 03:16 PM Thread Starter
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I haven’t tested the new assembly but I’m doing that next. I found a company called injector RX that will clean and test the injectors for about $18.00 each. I’m going to send the injectors to them and see what the result is.

I did take the new regulator off the new assembly and put it on the old one that I knew was getting good fuel pressure and had the same problem.
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post #8 of 10 (permalink) Old 08-10-2019, 04:10 PM Thread Starter
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Fuel issue? **SOLVED**

Alright just wanted to update and say issue is solved! Ended up taking the tank off, cleaning it out, and replaced injectors.

I saw where someone on here found a Honda Civic injector that was identical to the Suzuki oem injectors. So I took a chance and ordered two from rock auto. Cost me about $40.00

Put it all back together and I’m on the road once again. I’ll put pictures of the injectors below.

027B0328-E08E-419D-A223-41E687DA1181_1565464193748.jpg6287BE92-D40E-4F7E-9770-0BB73BFB1A68_1565464174628.png6287BE92-D40E-4F7E-9770-0BB73BFB1A68_1565464174628.png6287BE92-D40E-4F7E-9770-0BB73BFB1A68_1565464174628.png
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post #9 of 10 (permalink) Old 08-10-2019, 04:17 PM
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Excellent job. Enjoy and ride safe.

I can head East or West, it doesn't matter as long as it's on 2 wheels.
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post #10 of 10 (permalink) Old 08-12-2019, 04:05 PM
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Quote:
Originally Posted by Gnet View Post
Alright just wanted to update and say issue is solved! Ended up taking the tank off, cleaning it out, and replaced injectors.

I saw where someone on here found a Honda Civic injector that was identical to the Suzuki oem injectors. So I took a chance and ordered two from rock auto. Cost me about $40.00

Put it all back together and Iím on the road once again. Iíll put pictures of the injectors below.

Attachment 129734Attachment 129732Attachment 129732Attachment 129732
Good to hear the Honda injectors worked out. I was looking into those when I was chasing my problem, however when I tested them on the bike I still had low fuel pressure (I should have checked that first), since it of course still ran like crap I couldn't really confirm or deny if the Honda injectors were an interchange. Physically they are identical and some anecdotal evidence I found suggested the flow rates were the same (Civic has 400cc cylinders, just like the C50), but couldn't really confirm or deny. Once I discovered the fuel pressure issue I fixed that and put the OE injectors back in, just to rule out the Civic injectors possibly not being a match. The bike ran great so I didn't mess with it further to try the Civic ones to see if it still ran great (ended up returning them).
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