The Suzuki VX800, a naked roadster produced from 1990 to 1997, holds a special place in the hearts of many riders. Its torquey V-twin engine, comfortable riding position, and classic styling made it a versatile machine for commuting, touring, and weekend blasts. However, like any motorcycle, the VX800 has its share of common problems that potential and current owners should be aware of. Understanding these issues can help you make informed decisions, perform preventative maintenance, and keep your VX800 running smoothly for years to come.

The Heart of the Matter: Engine Quirks and Concerns

The VX800's 805cc V-twin engine is generally reliable, but it's not without its potential pitfalls. These issues are often age-related and stem from the inherent design or the effects of time on its components.

Cam Chain Tensioner (CCT) Woes: The VX800's cam chain tensioner is a common source of concern. The original design is a spring-loaded, ratchet-type tensioner that can fail, leading to excessive cam chain noise and, in severe cases, engine damage. Signs of a failing CCT include a rattling or ticking sound, especially at idle or low RPM.

  • Solution: Replacing the original CCT with a manual cam chain tensioner is a popular and often recommended upgrade. Manual tensioners allow you to precisely adjust the tension on the cam chain, eliminating the risk of failure associated with the automatic unit. Regularly checking and adjusting the manual tensioner is crucial.

Vacuum Leaks and Carburetor Complications: The VX800 uses two Mikuni BDST38 carburetors. Over time, the rubber components in these carburetors can degrade, leading to vacuum leaks. Vacuum leaks can cause a variety of problems, including:

  • Poor idling: The engine may struggle to maintain a steady idle speed.

  • Hesitation or stalling: The bike may hesitate or stall during acceleration.

  • Poor fuel economy: Vacuum leaks can disrupt the air-fuel mixture, leading to decreased fuel efficiency.

  • Difficult starting: The bike may be hard to start, especially when cold.

  • Solution: Regularly inspect the carburetor boots and vacuum lines for cracks or leaks. Replacing these components with new ones is often necessary to restore proper carburetor function. A carburetor rebuild, including cleaning and replacing worn jets and needles, can also address many carburetor-related issues. Synchronizing the carburetors after a rebuild is essential for smooth engine performance.

Oil Leaks: A Common Sight: VX800s, especially those with higher mileage, are prone to oil leaks. Common areas for leaks include:

  • Valve cover gaskets: These gaskets can harden and crack over time, allowing oil to seep out.

  • Base gaskets: The gaskets between the cylinder and the engine case can also leak.

  • Oil seals: The oil seals around the crankshaft and camshaft can wear out, leading to leaks.

  • Solution: Inspect the engine regularly for signs of oil leaks. Replacing the affected gaskets or seals is usually the solution. When replacing gaskets, ensure the surfaces are clean and properly prepared. Consider using a high-quality gasket sealant to ensure a good seal.

Fuel Pump Issues: Although not universally common, the fuel pump on the VX800 can occasionally fail. Symptoms include fuel starvation, especially at higher RPM, and difficulty starting.

  • Solution: Testing the fuel pump's output pressure is the first step. If the pump is faulty, replacement is the best option. Aftermarket fuel pumps designed for similar motorcycles can often be used as a cost-effective alternative to the original Suzuki pump.

Electrical Gremlins: Keeping the Lights On

The VX800's electrical system is generally reliable, but some common issues can arise.

Charging System Problems: The charging system, consisting of the stator, regulator/rectifier, and battery, is crucial for keeping the bike running. Problems in this system can lead to a dead battery and a non-starting bike.

  • Stator Failure: The stator generates the electricity to charge the battery. It can fail due to overheating or insulation breakdown.

  • Regulator/Rectifier Failure: The regulator/rectifier converts the AC voltage from the stator to DC voltage and regulates the voltage to prevent overcharging the battery. It can fail due to overheating or component failure.

  • Solution: Testing the output of the stator and the regulator/rectifier is essential to diagnose charging system problems. A multimeter can be used to measure voltage and resistance. Replacing faulty components with new or refurbished units is the solution. Upgrading to a modern MOSFET regulator/rectifier is a popular upgrade that improves reliability and reduces heat.

Wiring Harness Issues: Over time, the wiring harness can become brittle and corroded, leading to electrical problems. Common areas for problems include:

  • Connectors: Connectors can become corroded, leading to poor connections.

  • Grounding points: Poor grounding can cause a variety of electrical issues.

  • Damaged wires: Wires can become damaged due to chafing or exposure to the elements.

  • Solution: Inspect the wiring harness regularly for signs of damage. Clean and lubricate connectors with dielectric grease to prevent corrosion. Ensure all grounding points are clean and secure. Repair or replace damaged wires as needed.

Chassis and Suspension: Handling the Road

The VX800's chassis and suspension are generally robust, but some components can wear out over time.

Fork Issues: The front forks can develop problems, including:

  • Leaking fork seals: The fork seals can wear out, leading to oil leaks.

  • Worn bushings: The bushings inside the forks can wear out, leading to excessive play.

  • Sagging springs: The fork springs can sag over time, leading to poor handling.

  • Solution: Replacing the fork seals is a common maintenance task. Replacing the bushings and springs can also improve handling. Upgrading to progressive fork springs can provide a more comfortable and controlled ride. Regularly checking the fork oil level and condition is also important.

Rear Shock Wear: The rear shock absorber can wear out over time, leading to a bouncy or unstable ride.

  • Solution: Replacing the rear shock with a new or rebuilt unit is the solution. Upgrading to an aftermarket shock can provide improved performance and adjustability.

Brake Problems: The VX800's brakes are adequate, but they can suffer from common issues.

  • Worn brake pads: The brake pads can wear out over time, reducing braking performance.

  • Sticking calipers: The brake calipers can become sticky, leading to uneven braking.

  • Contaminated brake fluid: Brake fluid can absorb moisture over time, reducing braking performance.

  • Solution: Regularly inspect the brake pads and replace them as needed. Clean and lubricate the brake calipers to prevent them from sticking. Flush and replace the brake fluid every two years to maintain optimal braking performance. Consider upgrading to stainless steel brake lines for improved braking feel and performance.

Aesthetics and Bodywork: Maintaining the Look

The VX800's bodywork is generally durable, but some issues can arise.

Paint Fading and Scratches: The paint can fade and become scratched over time, especially if the bike is exposed to the elements.

  • Solution: Regular washing and waxing can help protect the paint. Touch-up paint can be used to repair minor scratches. A professional paint job can restore the bike's original appearance.

Plastic Cracks and Damage: The plastic bodywork can become cracked or damaged due to impacts or exposure to the sun.

  • Solution: Repairing minor cracks with plastic epoxy is possible. Replacing damaged bodywork with new or used parts may be necessary.

Frequently Asked Questions

  • Why does my VX800 rattle at idle? This is often due to a failing cam chain tensioner. Consider replacing it with a manual tensioner.

  • My VX800 hesitates when I accelerate. What could be the cause? Vacuum leaks in the carburetor system are a likely culprit. Inspect and replace any cracked or damaged vacuum lines and carburetor boots.

  • My battery keeps dying. What should I check? Test the stator and regulator/rectifier to ensure they are functioning properly. Also, check for parasitic drains on the battery.

  • How often should I change the oil on my VX800? It is generally recommended to change the oil and filter every 3,000 miles or annually, whichever comes first.

  • Where can I find parts for my VX800? Online retailers specializing in motorcycle parts, such as eBay, Partzilla, and CMSNL, are good sources. Also, check with local motorcycle salvage yards.

Keeping Your VX800 Alive and Kicking

The Suzuki VX800, despite its age, remains a capable and enjoyable motorcycle. By understanding the common problems and performing regular maintenance, you can keep your VX800 running smoothly and reliably for many years to come. Focus on the engine and electrical system, as these areas are most prone to age-related issues.