The Suzuki Intruder, particularly the VL800 (Volusia) and VL1500 models, has captivated riders with its classic cruiser styling, comfortable ride, and relatively affordable price point. However, like any motorcycle, the Intruder isn't immune to its share of problems. Understanding these common issues, from electrical gremlins to mechanical quirks, can save you time, money, and frustration, keeping you on the road longer and enjoying the open air. Let's dive into the typical troubles that Intruder owners face and how to tackle them.

Electrical Issues: When the Lights Go Dim (and Worse)

Electrical problems are a frequent complaint among Intruder owners, impacting everything from starting the bike to running smoothly. Several components are often implicated:

  • Stator Failure: This is arguably the most notorious electrical problem. The stator is responsible for charging the battery while the engine is running. When it fails, the battery eventually drains, leaving you stranded. Symptoms include a weak battery, dimming lights, and eventually, the bike refusing to start. Testing the stator's output voltage with a multimeter is the best way to diagnose this issue. Unfortunately, replacing the stator often requires removing the engine, making it a somewhat involved repair. Many owners opt for aftermarket stators known for their improved durability.

  • Voltage Regulator/Rectifier Problems: The voltage regulator/rectifier regulates the voltage coming from the stator, preventing it from overcharging the battery. A faulty regulator can lead to overcharging (boiling the battery) or undercharging (draining the battery). Look for signs of a swollen or leaking battery, or use a multimeter to check the charging voltage at the battery terminals while the engine is running.

  • Wiring Harness Issues: Age and exposure to the elements can take a toll on the Intruder's wiring harness. Corrosion, frayed wires, and loose connections can cause a variety of electrical problems, from intermittent lights to complete electrical failure. Thoroughly inspect the wiring harness, paying close attention to connectors and areas prone to rubbing. Clean corroded connections with electrical contact cleaner and repair or replace damaged wires as needed. Applying dielectric grease to connectors can help prevent future corrosion.

  • Battery Woes: While seemingly obvious, battery problems are common. A weak or failing battery can manifest as difficulty starting, especially in cold weather. Ensure your battery is properly maintained and charged. Consider a battery tender if you don't ride frequently.

  • Starter Relay/Solenoid Failure: This little device is responsible for sending power to the starter motor. When it fails, you'll hear a clicking sound when you press the starter button, but the engine won't crank. Testing the relay with a multimeter can confirm the diagnosis.

Fuel System Foibles: Keeping the Engine Fed

The Intruder's fuel system, particularly on older models, can present some challenges:

  • Carburetor Issues (Pre-Fuel Injection Models): If you own a carbureted Intruder, you might encounter problems such as clogged jets, a sticking float, or a vacuum leak. These issues can lead to poor performance, rough idling, and difficulty starting. Cleaning the carburetor thoroughly and replacing worn parts is often the solution. Ensure the fuel lines are in good condition and that the fuel filter is clean.

  • Fuel Pump Problems: The fuel pump is responsible for delivering fuel from the tank to the engine. A failing fuel pump can cause the engine to stumble, lose power, or stall completely. Listen for a weak or unusual sound from the fuel pump when you turn the key. Testing the fuel pressure can help diagnose a failing pump.

  • Fuel Injector Problems (Fuel Injected Models): While less common than carburetor issues, fuel injectors can become clogged or malfunction, leading to similar symptoms as carburetor problems. Fuel injector cleaner can sometimes resolve minor clogs. However, severely clogged or damaged injectors may need to be professionally cleaned or replaced.

  • Fuel Tank Rust and Debris: Rust and debris in the fuel tank can clog the fuel filter and fuel pump, leading to fuel delivery problems. Inspect the inside of the fuel tank for rust and debris. If necessary, clean the tank thoroughly and install a new fuel filter.

Clutch Concerns: Slipping and Sticking

The clutch is a critical component for smooth shifting and power transfer. Here's what to watch out for:

  • Clutch Slippage: This occurs when the clutch plates don't fully engage, causing the engine to rev without transferring power to the rear wheel. Clutch slippage can be caused by worn clutch plates, contaminated clutch plates (oil or grease), or a weak clutch spring. Replacing the clutch plates and springs is typically the solution.

  • Clutch Drag: This occurs when the clutch plates don't fully disengage, making it difficult to shift gears or find neutral. Clutch drag can be caused by warped clutch plates, a sticking clutch cable, or low clutch fluid (if equipped with a hydraulic clutch). Inspect the clutch cable for damage or binding and lubricate it as needed.

  • Clutch Cable Issues: The clutch cable connects the clutch lever to the clutch mechanism. A frayed, stretched, or damaged clutch cable can cause difficulty engaging or disengaging the clutch. Replace the clutch cable if it shows signs of wear or damage.

Drivetrain Dilemmas: Shaft Drive Woes

The Intruder's shaft drive system offers smooth and reliable power transfer, but it's not without its potential issues:

  • Final Drive Oil Leaks: The final drive, located at the rear wheel, contains oil that lubricates the gears. Leaks can occur from the seals around the final drive unit. Inspect the final drive for signs of oil leaks. Replacing the seals is typically the solution.

  • Final Drive Gear Wear: Over time, the gears in the final drive can wear, leading to noise and vibration. Regularly changing the final drive oil can help prolong the life of the gears. Listen for unusual noises coming from the final drive.

  • U-Joint Problems: The U-joints connect the driveshaft to the transmission and final drive. These joints can wear out over time, leading to vibration and noise. Inspect the U-joints for play and lubricate them as needed.

Suspension Setbacks: A Bumpy Ride

Suspension problems can significantly impact the Intruder's handling and comfort:

  • Fork Seal Leaks: The fork seals prevent oil from leaking out of the front forks. Leaking fork seals can lead to poor handling and a messy front end. Replacing the fork seals is a common maintenance task.

  • Worn Shocks: The rear shocks provide damping and support for the rear of the bike. Worn shocks can lead to a bouncy ride and poor handling. Replacing the shocks is often the best solution.

  • Swingarm Bushing Wear: The swingarm bushings connect the swingarm to the frame. Worn bushings can lead to play in the rear suspension and poor handling. Replacing the swingarm bushings can restore proper handling.

Brake Blunders: Stopping Power Problems

Reliable brakes are essential for safety. Here are some common brake-related issues:

  • Worn Brake Pads: Brake pads wear down over time and need to be replaced. Inspect the brake pads regularly and replace them when they reach the wear limit.

  • Sticking Brake Calipers: Brake calipers can stick, causing the brakes to drag and overheat. Cleaning and lubricating the brake caliper pistons can often resolve this issue.

  • Brake Line Problems: Brake lines can become cracked or damaged, leading to leaks and reduced braking performance. Inspect the brake lines regularly for damage and replace them as needed.

  • Master Cylinder Issues: The master cylinder is responsible for generating pressure in the brake system. A faulty master cylinder can lead to weak or spongy brakes. Rebuilding or replacing the master cylinder may be necessary.

Frequently Asked Questions

  • Why does my Intruder keep draining the battery? This is often due to a faulty stator or voltage regulator. Have these components tested to identify the culprit.

  • My Intruder is hard to start when it's cold. What could be the problem? Possible causes include a weak battery, clogged carburetor jets (on carbureted models), or a faulty choke. Check these components and ensure they are functioning properly.

  • What is the best way to prevent electrical problems on my Intruder? Regularly inspect the wiring harness, clean corroded connections, and ensure the battery is properly maintained. Consider using dielectric grease on connectors.

  • How often should I change the final drive oil on my Intruder? Refer to your owner's manual for the recommended service intervals. Generally, changing the final drive oil every 12,000 to 15,000 miles is a good practice.

  • My Intruder's clutch is slipping. What should I do? Clutch slippage is often caused by worn clutch plates. Replacing the clutch plates and springs is typically the solution.

Conclusion

While the Suzuki Intruder offers a fantastic riding experience, being aware of these common problems can help you diagnose and address issues promptly. Regular maintenance, careful observation, and a willingness to tackle minor repairs can keep your Intruder running smoothly for years to come. Remember to consult your owner's manual and seek professional help when needed to ensure your bike stays in top condition.