Suzuki Intruder 800 Problems

The Suzuki Intruder 800, a classic cruiser, offers a comfortable ride and distinctive styling that has charmed riders for years. However, like any machine, it has its share of quirks and potential problems. Understanding these common issues empowers owners to maintain their bikes effectively, troubleshoot problems efficiently, and ultimately, enjoy their Intruder 800 for many years to come. Let’s dive into some of the most frequently encountered challenges and how to address them.

Carburetor Conundrums: When Your Intruder Won't Cooperate

The Intruder 800, particularly models before fuel injection became standard, relies on carburetors for fuel delivery. While generally reliable, carburetors can be sensitive to environmental factors and fuel quality, leading to a range of issues.

• Starting Problems (Especially in Cold Weather): A common complaint is difficulty starting, especially when the temperature drops. This is often due to a lean fuel mixture, meaning there's not enough fuel compared to air.

  • Solution: Try using the choke (enrichment circuit) more aggressively. If that doesn't work, the carburetor might need cleaning or adjustment. Look for clogged jets or passages. Carburetors are very sensitive to varnishing from old fuel. A pilot jet is very small and the first to clog.

• Rough Idling: An unstable or excessively low idle speed can indicate a problem with the carburetor's idle circuit.

  • Solution: Check the idle mixture screw. It may need to be adjusted slightly. Also, a vacuum leak can cause rough idling, so inspect the intake manifolds and vacuum lines for cracks or loose connections.

• Hesitation or Stumbling During Acceleration: If your Intruder hesitates or stumbles when you open the throttle, it could be a sign of a dirty or partially clogged carburetor jet.

  • Solution: A thorough carburetor cleaning is often necessary. Pay close attention to the main jet and needle jet, as these components play a crucial role in fueling during acceleration.

• Popping or Backfiring: Popping or backfiring, especially on deceleration, can indicate a lean fuel mixture.

  • Solution: Check for exhaust leaks, as these can introduce extra air into the exhaust system, leaning out the mixture. Also, revisit the carburetor settings and ensure they are within the manufacturer's specifications.

Pro Tip: Using a fuel stabilizer in your gasoline, especially during periods of storage, can prevent carburetor problems. Stabilizer prevents the fuel from breaking down and leaving deposits that clog vital components.

Electrical Gremlins: Chasing Down the Voltage

Electrical problems can be frustrating, as they can manifest in various ways and be difficult to diagnose. The Intruder 800 is no exception, and here are some common electrical issues.

• Battery Issues: Weak or dead batteries are a frequent problem, especially if the bike sits unused for extended periods.

  • Solution: Regularly check the battery's voltage. If it's consistently low, consider replacing it. Use a battery tender when the bike is not in use to keep the battery charged and healthy.

• Charging System Problems: If your battery keeps dying even after being charged, the charging system might be at fault. This includes the alternator, regulator/rectifier, and wiring.

  • Solution: Use a multimeter to test the output of the alternator and the voltage regulation of the regulator/rectifier. A faulty regulator/rectifier is a common culprit. Also, check the wiring harness for any loose connections or damaged wires.

• Starter Problems: Difficulty starting, accompanied by a clicking sound, can indicate a problem with the starter motor or solenoid.

  • Solution: Check the starter solenoid for proper function. If it's clicking but not engaging, it might need replacement. If the starter motor itself is faulty, it might need to be rebuilt or replaced. Ensure all connections to the starter are clean and tight.

• Wiring Issues: Over time, the wiring harness can become brittle and develop cracks or breaks, leading to intermittent electrical problems.

  • Solution: Inspect the wiring harness for any signs of damage. Pay close attention to areas where the harness is routed near hot engine components or sharp edges. Use electrical tape or heat shrink tubing to repair any damaged wires.

Important Note: When working on electrical systems, always disconnect the battery to prevent short circuits and electrical shocks.

Clutch Concerns: Slipping and Sticking

The clutch is responsible for transferring power from the engine to the transmission. Over time, the clutch plates can wear down, leading to slipping or sticking.

• Clutch Slipping: If the engine revs up without a corresponding increase in speed, the clutch is likely slipping.

  • Solution: Check the clutch cable for proper adjustment. If the cable is too tight, it can prevent the clutch from fully engaging. If the clutch plates are worn, they will need to be replaced. Also, ensure that you are using the correct type of oil, as some oils can cause clutch slippage.

• Clutch Sticking: If the clutch lever feels sticky or doesn't return smoothly, it could be due to a worn or contaminated clutch cable.

  • Solution: Lubricate the clutch cable with a cable lubricant. If the cable is heavily corroded, it might need to be replaced. Also, inspect the clutch lever pivot point for any signs of corrosion or binding.

• Hard Shifting: Difficulty shifting gears can sometimes be related to the clutch.

  • Solution: Ensure the clutch is fully disengaging when you pull the lever. If not, re-adjust the clutch cable. Low or dirty transmission oil can also contribute to hard shifting, so check the oil level and condition.

Cooling System Challenges: Keeping Your Intruder Cool

The Intruder 800 is liquid-cooled, which helps to maintain a stable engine temperature. However, the cooling system can experience problems that lead to overheating.

• Overheating: If the engine temperature gauge climbs into the red zone, it's a sign of overheating.

  • Solution: Check the coolant level in the radiator and overflow tank. If the coolant is low, top it off with the correct type of coolant. Inspect the radiator for any obstructions, such as dirt or debris. Ensure the cooling fan is functioning properly. If the fan is not turning on, check the fan switch and wiring.

• Coolant Leaks: Coolant leaks can lead to low coolant levels and overheating.

  • Solution: Inspect the radiator hoses, water pump, and cylinder head for any signs of leaks. Tighten any loose hose clamps. If a hose is cracked or damaged, replace it. A leaking water pump might need to be rebuilt or replaced.

• Thermostat Problems: A faulty thermostat can prevent the engine from reaching its operating temperature or cause it to overheat.

  • Solution: Test the thermostat to ensure it is opening and closing properly. If it's not functioning correctly, replace it.

Preventative Measure: Regularly flush and replace the coolant to prevent corrosion and buildup in the cooling system.

Final Drive Frustrations: Shaft Drive Maintenance

The Intruder 800 uses a shaft drive, which is generally low-maintenance compared to a chain drive. However, it still requires periodic attention.

• Oil Leaks: Oil leaks from the final drive unit can indicate a worn seal.

  • Solution: Inspect the final drive unit for any signs of leaks. Replace any worn seals to prevent further oil loss.

• Noise: Unusual noises from the final drive unit, such as whining or grinding, can indicate worn bearings or gears.

  • Solution: Have the final drive unit inspected by a qualified mechanic. Worn bearings or gears will need to be replaced.

• Oil Changes: The final drive oil needs to be changed periodically to ensure proper lubrication.

  • Solution: Follow the manufacturer's recommended maintenance schedule for final drive oil changes. Use the correct type of oil.

Frequently Asked Questions

• Why is my Intruder 800 hard to start when it's cold? A lean fuel mixture is often the culprit. Use the choke more aggressively and consider a carburetor cleaning if the problem persists.
• What type of oil should I use in my Intruder 800? Consult your owner's manual for the recommended oil type and viscosity. Using the wrong oil can cause clutch slippage or other problems.
• How often should I change the oil in my Intruder 800? Follow the manufacturer's recommended maintenance schedule. Generally, oil changes are recommended every 3,000 to 5,000 miles.
• My Intruder 800 is overheating. What should I do? Check the coolant level, inspect the radiator for obstructions, and ensure the cooling fan is functioning properly. If the problem persists, consult a mechanic.
• How do I adjust the clutch cable on my Intruder 800? Loosen the locknut on the clutch cable adjuster and turn the adjuster until you have the proper amount of free play in the clutch lever. Then, tighten the locknut.

Keeping Your Intruder Running Smoothly

Addressing these common problems proactively can significantly extend the life and enjoyment of your Suzuki Intruder 800. Regular maintenance, careful observation, and prompt attention to any issues will keep your classic cruiser running smoothly for years to come.