2003 Suzuki VL800 recall - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #1 of 26 (permalink) Old 03-17-2011, 01:35 PM Thread Starter
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2003 Suzuki VL800 recall

Hello, I am new to this forum and have a problem with my bike and am looking for advice. I took my bike into the local dealership to get checked out because the electrical system is shorting out occasionally all electrical will die and engine will cut out. They told me the wiring harness was routed improperly causing it to rub and short out, melting the ignition switch which will be a 400$ repair. When I look online for VL800 recalls I find one for 2005 2006 VL800 that says this,

"ON CERTAIN MOTORCYCLES, THE IGNITION SWITCH WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED AT THE TIME OF PRODUCTION. IF THE WIRING HARNESS IS NOT ROUTED PROPERLY, IT CAN RUB AGAINST THE CLUTCH CABLE/THROTTLE CABLE.

Action Needed To Fix It:
DEALERS WILL RE-ROUTE THE IGNITION SWITCH WIRING HARNESS AND REPLACE THE LOCK SET INCLUDING THE IGNITION SWITCH ALONG WITH THE CLUTCH CABLE/THROTTLE CABLE FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 6, 2006. OWNERS MAY CONTACT SUZUKI AT 714-572-1490. "

Practically word for word, this is what the shop said was wrong with my ride, because they needed to reroute the wiring harness so it would not rub and short out again. I told the service dept. about this recall and they said they would try to talk to Suzuki, in your guys experience, do you think they will cover this? It sounds like the exact same problem and hopefully they will see this.

Thanks,

Bill
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post #2 of 26 (permalink) Old 03-17-2011, 01:56 PM
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I have a 2003 VL800 that I bought new, and the wiring harness is just fine. No electrical problems since 2003. Actually, no problems whatsoever with this bike. Having said that, I am skeptical about the dealer estimate of $400 should your bike indeed require this work.

p.s. I was not notified about a 2003 recall

Last edited by T-Hall; 03-17-2011 at 01:59 PM.
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post #3 of 26 (permalink) Old 03-17-2011, 02:11 PM Thread Starter
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Caused by an improperly routed wiring harness..... I'm pretty sure I can read and thats exactly what the recall says but diff year.
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post #4 of 26 (permalink) Old 03-17-2011, 02:14 PM Thread Starter
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I'm confused, are you doubting my electrical shortage? Doubting that is whats wrong with it? Help would be appreciated, not skepticism.
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post #5 of 26 (permalink) Old 03-17-2011, 02:19 PM
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1st Welcome new members.
2nd, I really doubt Suzuki will cover the repair as the bike is 8 yrs old and the recall did not include 2003, just 05-06.
3rd, does the $400 cover the repair or just the labor?
4th, some have tried, alot have failed dealing with MR. Suzuki so good luck

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post #6 of 26 (permalink) Old 03-17-2011, 02:21 PM Thread Starter
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379 for labor and parts out the door, it just irritates me when I read that recall it's word for word what the dealer said was wrong when they called me. Been in the shop for two weeks because they had to order the ignition switch....
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post #7 of 26 (permalink) Old 03-17-2011, 02:22 PM Thread Starter
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Thanks for the welcome, just trying to get some answers.
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post #8 of 26 (permalink) Old 03-17-2011, 03:30 PM
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That sucks!
But thanks for the info, my buddies is a 2005 and it's in my shop right now. I'll go check it's routing!

Thanks for the heads up!

Why use a big word when a diminutive utterance would suffice?
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post #9 of 26 (permalink) Old 03-17-2011, 03:38 PM
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Newb fight!!!!!!

Since the recall doesn't cover '03 I don't think Suzuki will do jack for you. Sorry. That being said, I would just get the parts from them and do this yourself. It isn't hard to replace the ignition and routing of the wires can be safely done with a little common sense.

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post #10 of 26 (permalink) Old 03-17-2011, 09:17 PM
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I have and 03, no issues with mine at all, I did have a tail light wiring issues but that was because a pot hole caused me to bottom out on my rear wheel well and knocked my wireing harness loose, rear tire rubbed wires through, I had to do a road side rewire. not fun. Good luck. and welcome

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