Faulty Ignition Switch- 2003 Volusia Suzuki

[strm4]

I have a 2003 Volusia Suzuki which I bought new. I've had no problems with this bike and have put 21,000 km on it. Three months ago I was riding it when all of a sudden the engine shut off and the lights went out. I pulled over and everything came back on. I've checked all the wiring and fuses and everything looks ok. The motorcycle has been intermittently shutting off and coming on again in about 2 seconds. Two weeks ago it died while I was traveling along a major highway. I've checked the wiring diagram and it appears everything goes through the ignition switch and then back out to power everything. Is anyone having a similar problem with their 2003 Suzuki volusia motorcycle.? If so, what was your fix ?

[Danr]

If it is only cutting out while bike is in motion then you have a circuit going open because of vibration. The ignition switch is a good place to start. Also the battery and cables. I wouldnt put off getting it fixed. Imagine accelerating on a super slab on ramp with a cage on your rear and have it cut out (not pretty) Sorry I cant pinpoint it for you.

[tlwisner]

Suzuki did just have a recall for ignition switches on Burgmans. Maybe it's the same switch? I dunno.

[strm4]

The problem started off while I was riding. It is now happening while I'm sitting on the bike stationary. The engine and the headlights cut out for about two seconds and come back on. I have a digital display on my gas tank. The numbers reset as if you just tuirned the ignition switch on. I saw the recall Suzuki has on the scooter. The same problem is happening to my bike. The entire bike was checked. The battery connections were checked and every wire connection was taken apart and sprayed with corrosion spray.
It is very intermittent. I tried to make it fail without success. I've emailed Suzuki Canada to try and get them to repair this problem under warranty. I'm still waiting for a reply. I'm leaning towards replacing the ignition switch. What do you think ?

[bud van houten]

i have a 2000 intruder lc that quit on me last week. my battery drained and killed everything. thought sure i was going to have to buy a new stator or rectifier. had it checked and they said it was charging fine. before i took it to the shop, i pulled the retifier connectors and found the red one had been hot at one time. the black plastic connector had actually melted a little, but not the red wire itself, so i think i had an arcing in the connector that caused the battery to drain. i cleaned the connector and put some of the grease that's suppose to help keep it dry. rode over a hundred miles tonight with all my lights on and no problem. might want to check all your connectors. later, bud

[DrBob]

I know several people who have had electrical demons like this on Volusias and Intruders. All were caused by a bad connection at the battery, more often than not the negative side. Remove the wires, clean them and the terminals with a file or wire brush, reconnect them nice and tight, and use a drop of thread locker or mail polish to keep them tight. Works like a champ.

[strm4]

I got a reply to my problem with the ignition switch from Suzuki. They advised the bike should go to a Suzuki Dealer and pay them to look at it. I advised the Customer Service girl I had a mechanic look at the bike and all the connections are ok. The problem is the ignition swtch. They don't recognize mechanics unless they work at a Suzuki Dealer. All I wanted is the swtch to be replaced. I would have it put on my bike for free. Suzuki would not go for that. It has to go to a dealer and pay him to try and find the problem. Once he finds the problem, maybe, because it is so intermittent. The dealer would have to ask Suzuki to have the part replaced for free and they would cover the cost. I was also advised by Suzuki they may not cover the cost because the bike is no longer under warranty. So bottom line. I can buy the ignition switch and have it installed for free or pay a dealer big dollars to look over the bike and have them install it and then ask Suzuki would you cover the cost. Suzuki thanks for nothing. I'll buy a bike next time from a manufacturer that builds good bikes and looks after their customers. This is a major problem on a two year old bike.

[strm4]

During the weekend when the weather was great, I could see bikes riding all over the place. I should of been riding my Suzuki. Instead, I was repairing it and here is the fix. I removed the ignition switch and found the red wire( power ) was a little discoloured just ahead of the connector leading to the ignition switch. I jumpered the two red wires, before the connector leading from the battery and just ahead of the discoloured part on the ignition switch side. cutting the red wire on the ignition side, bypassing the connector, and the bike in back in operation. I have been riding my bike 250 to 300 km a day without any power loss. This has fixed my problem. The ignition switch, wire connection, caused a major problem and a $2 connector ( crimp style) and a 6 inch wire fixed my bike. I'm enjoying fall riding and can't wait for the winter to come.

[blackie1491]

Good job. I am glad your back on the road.