Stalling,fuel smell, sputtering - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 3 (permalink) Old 09-10-2019, 10:21 PM Thread Starter
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Exclamation Stalling,fuel smell, sputtering

hello all, here's what I got going on. I have a 2003 Volusia 800. I have been having issues with it sputtering, bucking, stalling with hard restart. strong odor of fuel, and just general no starts till the battery is dead. So, after some fuel line replacements, vacuum line replacements I found rusty gas in my tank. so.....drained it all out, soaked in rust remover and got it all out (used a bore scope) flushed the lines, cleaned the fuel pump under the battery box. cleaned out the carb, blew through the gas line to see if I had flow. adjusted the carb (2 1/2) turns and idle adjustment screw. thought I had it al set until I took it out. SAME ISSUE!!! I have checked every line, every clamp every bolt. any ideas? I was going with the fuel pump is bad and the flaps (diaphragms?) are not opening as they should. but would that give me the strong fuel smell when it stalls? any information would be helpful and sorry for the life story lol
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post #2 of 3 (permalink) Old 09-10-2019, 10:32 PM
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hang in there...someone will come along and hopefully offer some suggestions that may help...good luck.

Whats the big hurry...slow down and enjoy the ride!

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post #3 of 3 (permalink) Old 09-11-2019, 08:14 AM
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Rust in the tank is cancer. Once it starts, it spreads and affects everything it touches. There are no fuel filters on the bike, so anything that the gas touched, needs to come out of the bike. That includes removing the tank and COMPLETELY disassembling the vacuum fuel pump AND remove, disassemble then rebuild the carb. You have a 16 year old bike too, so lord knows how long it was sitting with a rusty tank.

You will also need to have the tank relined, or else it will rust again.

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