Suzuki Volusia 800 Problems

The Suzuki Volusia 800, a cruiser celebrated for its classic styling and comfortable ride, enjoyed a successful production run and remains a popular choice on the used motorcycle market. However, like any machine, the Volusia 800 isn't without its quirks and potential problems. Understanding these issues can help prospective buyers make informed decisions and current owners troubleshoot common concerns, ensuring many more miles of enjoyable riding.

What Are the Most Common Volusia 800 Issues I Should Know About?

While the Volusia 800 is generally regarded as a reliable motorcycle, certain issues tend to surface more frequently than others. Being aware of these potential problems can allow you to proactively address them or factor them into your purchasing decision.

The Dreaded Stalling Problem: One of the most widely reported issues with the Volusia 800 is stalling, particularly at idle or low speeds. This can be unnerving, especially in traffic.

Fuel Injection Foibles: Although fuel injection is generally more reliable than carburetors, the Volusia 800's system can sometimes present challenges.

Electrical Gremlins: Like many motorcycles, the Volusia 800 can experience electrical issues, ranging from minor annoyances to more serious problems.

Final Drive Woes: The shaft drive system, while offering low maintenance, isn't immune to problems.

Let's Dive Deeper: The Stalling Saga

The stalling issue on the Volusia 800 is often attributed to a combination of factors, making it tricky to diagnose definitively. Here’s a closer look at the potential culprits:

Idle Air Control (IAC) Valve: The IAC valve controls the amount of air that bypasses the throttle plate at idle, ensuring a smooth engine speed. A dirty or malfunctioning IAC valve can prevent the engine from receiving enough air at idle, causing it to stall. Cleaning the IAC valve with a suitable solvent is often the first step in addressing stalling issues.
Throttle Position Sensor (TPS): The TPS provides the engine control unit (ECU) with information about the throttle position. A faulty TPS can send incorrect signals, leading to improper fuel delivery and stalling. Checking the TPS voltage with a multimeter can help determine if it's operating within the correct range.
Vacuum Leaks: Vacuum leaks can disrupt the air-fuel mixture, causing the engine to run lean and stall. Carefully inspect all vacuum hoses for cracks or disconnections. Using a can of carburetor cleaner around vacuum lines can help identify leaks – an increase in engine RPM indicates a leak.
Fuel Injector Issues: Clogged or malfunctioning fuel injectors can prevent the engine from receiving the correct amount of fuel, leading to stalling. Fuel injector cleaner added to the fuel tank can sometimes resolve minor clogs. In more severe cases, professional cleaning or replacement may be necessary.
Poor Fuel Quality: Using low-quality fuel can contribute to stalling problems. Always use fuel with the recommended octane rating. Avoid using fuel that has been sitting for an extended period, as it can degrade and cause issues.
ECU Issues (Rare): While less common, problems with the ECU can also cause stalling. This is usually diagnosed after ruling out other potential causes.

Fuel Injection Problems: More Than Just Stalling

Beyond stalling, the Volusia 800's fuel injection system can exhibit other issues:

Hard Starting: Difficulty starting the engine, especially when cold, can indicate a problem with the fuel injection system. This could be due to a faulty fuel pump, clogged fuel filter, or issues with the fuel injectors. Checking the fuel pressure can help diagnose fuel pump problems. Replacing the fuel filter is a relatively inexpensive and preventative maintenance task.
Poor Fuel Economy: A sudden drop in fuel economy can also point to fuel injection problems. This could be caused by leaking fuel injectors, a faulty oxygen sensor, or a malfunctioning TPS. Monitoring fuel consumption and comparing it to previous levels can help identify potential issues.
Hesitation or Surging: Hesitation during acceleration or surging at constant speeds can indicate problems with the fuel injection system. This could be due to a lean or rich fuel mixture caused by faulty sensors or injectors.

Electrical Gremlins: Chasing Those Phantom Issues

Electrical problems can be frustrating to diagnose, but here are some common issues and potential solutions:

Battery Issues: The battery is the heart of the electrical system. A weak or dying battery can cause a multitude of problems, including starting difficulties, dim lights, and erratic engine performance. Regularly check the battery voltage and condition. Use a battery tender to keep the battery charged when the motorcycle is not in use.
Charging System Problems: The charging system, consisting of the alternator (or stator), regulator/rectifier, and wiring, is responsible for keeping the battery charged. A faulty charging system can lead to a dead battery and other electrical issues. Using a multimeter to check the charging voltage while the engine is running can help diagnose charging system problems.
Wiring Issues: Over time, wiring can become corroded, damaged, or disconnected, leading to electrical problems. Carefully inspect the wiring harness for any signs of damage or corrosion. Use dielectric grease on electrical connections to prevent corrosion.
Fuse Problems: Blown fuses are a common occurrence and can indicate a short circuit or overload in the electrical system. Always replace blown fuses with fuses of the correct amperage rating. Investigate the cause of the blown fuse before replacing it.
Starter Issues: Difficulty starting the engine can be caused by a faulty starter motor or starter relay. Listen for a clicking sound when attempting to start the engine, which could indicate a faulty starter relay.

Final Drive Concerns: Keeping the Power Flowing Smoothly

While the shaft drive is generally low-maintenance, it's not entirely trouble-free:

Differential Oil Leaks: Leaks from the final drive differential can indicate worn seals or gaskets. Regularly check the differential oil level and inspect for leaks. Replacing worn seals or gaskets is necessary to prevent further damage.
Excessive Play or Noise: Excessive play in the final drive or unusual noises can indicate worn bearings or gears. Have the final drive inspected by a qualified mechanic if you notice any unusual play or noise.
Shaft U-Joint Problems: The universal joints (U-joints) in the driveshaft can wear out over time, leading to vibrations or noise. Lubricating the U-joints regularly can help extend their lifespan. Replacing worn U-joints is necessary to prevent further damage.

Prevention is Key: Maintaining Your Volusia 800

Regular maintenance is crucial for preventing many of the problems discussed above. Here are some key maintenance tasks:

Regular Oil Changes: Changing the engine oil and filter at the recommended intervals is essential for engine health.
Air Filter Maintenance: A clean air filter ensures proper airflow to the engine.
Spark Plug Replacement: Replacing the spark plugs at the recommended intervals ensures optimal combustion.
Fuel System Maintenance: Using fuel injector cleaner periodically can help keep the fuel injectors clean.
Battery Maintenance: Keeping the battery charged and clean is essential for electrical system health.
Final Drive Maintenance: Checking and changing the final drive oil at the recommended intervals is crucial for final drive health.
Regular Inspections: Performing regular inspections of the motorcycle can help identify potential problems before they become serious.

Frequently Asked Questions

Why does my Volusia 800 keep stalling? The stalling issue is often due to a dirty IAC valve, vacuum leaks, or a faulty TPS. Cleaning the IAC valve is a good first step.
What kind of oil should I use in my Volusia 800? Consult your owner's manual for the recommended oil type and viscosity. Using the correct oil is crucial for engine health.
How often should I change the oil in my Volusia 800? The oil change interval is typically specified in the owner's manual. Regular oil changes are essential for engine longevity.
My Volusia 800 is hard to start. What could be the problem? Hard starting can be caused by a weak battery, a faulty fuel pump, or clogged fuel injectors. Check the battery voltage and consider using fuel injector cleaner.
Is the Volusia 800 a reliable motorcycle? Yes, the Volusia 800 is generally considered a reliable motorcycle. Regular maintenance can help prevent many common problems.

In Conclusion

While the Suzuki Volusia 800 can experience certain issues, understanding these potential problems and implementing a proactive maintenance plan can significantly extend its lifespan and ensure many years of enjoyable riding. By addressing common issues like stalling, fuel injection problems, and electrical gremlins, you can keep your Volusia 800 running smoothly for years to come.