Question about 2003 Suzuki VL 800 Volusia

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What would cause my 2003 Suzuki Volusia 800cc to knock after spark plug replacement? We replaced the plugs and it knocked when we cranked the engine. We put in the old plugs and it still knocked. It almost sounds like something is on top of the piston, but didn't drop anything in the engine. The motorcycle ran fine before the spark plug change. I have 19,000 miles on the engine and keep up with maintenance and oil changes.

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SOURCE: where are the spark plugs

Follow the spark plug wires, you will find them. they are in the heads of the bike, somewhere, probably buried in a well, with the plug wire coming out. Check it out.

Posted on Aug 13, 2010

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My 2003 suzuki volusia 800 will not turn on it cranks but doesn't turn on

Hi Oscar, and the usual suspects are:
1. Fuel tank empty.
2. Fuel supply valve/petcock turned off.
3. Fouled spark plugs.
4. Engine flooded as a result of over use of enrichner.
5. Vacuum hose to fuel supply valve/petcock disconnected, broken, cracked, or pinched.
6. Fuel valve/petcock or filter clogged.
7. Discharged battery, loose, corroded or broken battery terminal connections especially the "NEGATIVE" cable inside the harness at both ends.
8. Loose or corroded wire connection at the coil, battery or plug between ignition sensor and module.
9. Spark plug cables in bad condition and shorting, cable connections loose, or connected to the wrong cylinders.
10. Ignition timing incorrect due to faulty ignition coil, ignition module or sensors (MAP, CMP CKP and/or BAS).
11. Sticky or damaged valve or pushrod wrong length.
12. Primary cam sprocket spline sheared or missing spacer.
13. Security alarm needs a reset.
For more information about your issue, please visit the websites below, Good luck and have a nice day.
2003 Suzuki Motorcycle Service Repair Workshop Manuals

Mar 10, 2014 | 2003 Suzuki VL 800 Volusia

1 Answer

What wll cause to the engine if knock sensor malfunction

The knock sensor tells the computer when to fire the spark plugs. A bad sensor can cause a misfire,ping and lose ignition timing. If you have a bad knock sensor you should replace it ASAP as it can cause damage to the engine.

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Check the wiring harnesses for bare or brittle spots. If none are found replace the spark plugs, all of them and spark plug wires. I know these are still fairly new but that is the next step. If you have over 60,000 miles on the vehicle it could be an issue with the timing chain but my experience tells me replace the crank Position sensor first if none of the other steps yield any results. Because these vehicles come with the power train warranties they do you can't really trust the Dealer Mechanics because they will do anything they can to prolong this to get the vehicle out of warranty.

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My car won't stay cranked after Iv'e changed my spark plugs. Did i knock anything loose?


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Where is the spark plug located on 2003 suzuki vl 800

You will need to partially or completely remove the fuel tank to get access to the spark plugs.

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How to replace spark plugs

The easiest way is to remove the gas tank to access the spark plugs.

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Where are the spark plugs located on a 2003 suzuki intruder motorcycle 800cc.

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Aug 13, 2010 | 2003 Suzuki VL 800 Volusia

1 Answer

How do i replace a knock sensor?

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do you have a k and n air filter,or the like?

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