2004 VL800 Turn signals - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum

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Old 03-18-2011, 07:02 AM   #1 (permalink)
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Default 2004 VL800 Turn signals

Hello. New to the forum but I need some help. This morning getting ready to leave for work. Had the bike warming in the driveway. Hear a thump from inside. Run outside to see the bike laying on the ground. Only damage as far as I can tell is the left side turn signals (front and back).

Did some quick browsing online and couldnt really find what I am looking for.

Does anyone have any for sale?
Could you point me in the direction to a website where I could get some that are relatively cheap?
Any aftermarket ones out there that you would recommend that are cheap?

Thanks for the help.
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Old 03-18-2011, 08:10 AM   #2 (permalink)
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Welcome to the site, pull up a chair, the beer is in the fridge.
You have been bit by the kickstand. Do a search on Kickstand mod to prevent it from happening again.

There is no place really cheap other than the swap meet here. 04-08 (maybe 09 but I am not sure) signals are the same. Fronts and rears are different but can be adapted if need be.

You can order them from someplace like RonAyers ($50-70 each)
Ronayers.com Microfiche Suzuki>Motorcycle>2004>VL800Z INTRUDER VOLUSIA>TURNSIGNAL FRONT REAR LAMP MODEL K4 K5

If you buy aftermarket ones here is some good info


Almost any turn signal will work. On the front they are 3 wire signals (ground, running, turn) on the back they are 2 wire (turn and ground). They use different bulbs (1157 front, 1156 rear)
Here is some other helpful info
Some are small and likely not DOT approved so if your state has "tight" inspections they may not pass.
There are multiple types of turn signals/running lights some can only be used for one function (turn OR running) others can be used for both functions.
1 wire - one function only - running light OR turn signal
Connections:
  • Connect the one wire to the brown wire on the bike for running light, the light green for Right turn, Black for left turn
    The negative (ground) is made through the mounting bolt, these lights won't work until you connect the bolt to a metal part on the bike.
2 wire - one function only - running light OR turn signal
Connections:
  • Connect the positive wire on the signal to the brown wire on the bike for running light, the light green for right turn, black for left turn.
    Connect the negative wire on the signal to the black wire with white stripe
2 wire - two function - running light AND turn signal
Connections:
  • Connect one of the positive wires on the signal to the brown wire on the bike for running light
    Connect the other positive wire on the signal to the light green on the bike for right turn, black for left turn.
    The negative (ground) is made through the mounting bolt, these lights won't work until you connect the bolt a metal part on the bike.
    If when you test the running light is brighter than the turn signal swap the two positive wires
3 wire - two function - running light AND turn signal
Connections:
  • Connect one of the positive wires on the signal to the brown wire on the bike for running light
    Connect the other positive wire on the signal to the light green for Right turn, Black for left turn.
    Connect the negative wire to the black with white stripe on the bike.
    If when you test the running light is brighter than the turn signal swap the two positive wires
The wires to the front signals are in the headlight
Headlight Bucket colors
Ground - Black with White stripe (multiple)
Light Green - Right turn signal
Black - Left Turn Signal
Gray - Running lights
Yellow - High Beam
White - Low Beam
Orange/Blue - Aux Power (light bar connector, seperate 10 amp fuse)

The rear signals are under the taillight
Brown (becomes gray at the tail light)---running light
Black with White stripe---ground
Black---left turn
Light Green---right turn
White Wire with Black stripe---brake light
In the headlight bucket there is
Orange-with-green is (+) and black-with-white is (-) with a white (usually) connector on the end. These are for wiring up the lightbar. They are on when the key is on. They are protected by a 10amp fuse.
Black with a white stripe is ground (-) thoughout the bike
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Old 03-18-2011, 10:56 AM   #3 (permalink)
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What was the damage to the turn signals. Broken stalk or did you also break the lenses. If the lenses are OK, save them. You'll be glad you did.

Also, each of the turn signals is a different part number (total of four). I don't recall if the Ron Ayers list differentiates left and right. If you state exactly what you're needing on your order, in the memo section, their Cust. Serv. people are great at making sure you get what you need (vs what you ask for). Don't ask me how I know.

I broke my left rear turn signal but was able to repair it with special loctite super glue (comes with a primer) and it's held up well so far. Beats shelling out 60-70 bucks per.
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Old 03-18-2011, 11:11 AM   #4 (permalink)
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Kickstand mod would be good also. I learned the hard way of why it needs to be done, but mine fall into soft mud, no damage.

Kickstand Mod: Step-by-Step, with photos
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Old 03-18-2011, 11:46 AM   #5 (permalink)
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Thanks for the information. I didnt get to check it out that in depth, as I was pissed off that it happened and had to get to work. I had my wife check before she left for work, and from what she said, one stem looks ok but the other may be shot. Ill look more this afternoon when I get home.

I may try to repair the one and replace the other. Before I jump and order new parts, I'm definately going to see what I can do temporarily to get out and ride today, since its 75 degrees here in the northeast.

The kickstand mod is something I am going to look into. I feel stupid for letting this happen. Everything was fine when I went inside and the next thing I know Im picking the bike up off my driveway. Could have been worse I guess.
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Old 03-18-2011, 12:09 PM   #6 (permalink)
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I just put these on:


They are a drag specialties light that go for ~$40 a set with both red and amber lenses. They are 1 1/2" with a short stalk. They also make "Deuce Style" lights that are a little bigger (1 3/4") for about the same price.


They aren't intended for our bikes, so you'll have to wire them like above, but they are a great alternative.
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Old 03-18-2011, 12:41 PM   #7 (permalink)
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Im assuming with most of the aftermarket parts, I would have to rewire them differently. Is this an easy task that I could do (I'm somewhat knowledgeable) or is this something very difficult that a dealer would have to do?

Fed-Where did you get the signals that are shown in the photo above?
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Old 03-18-2011, 12:57 PM   #8 (permalink)
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Custom Bullet Marker Light with Stud Mount | 306-876 | J&P Cycles

I checked my local shop yesterday and his price was a little less and no shipping.
So I ordered another set to replace my fronts.


They are fairly simple to add in. I have some pics of how I did it, but they are fairly crummy. Basically, I spliced a wire into the rear running light (for the brake) and split it. On those lights, the black wire is the 5w filament, so running light to black wire. Turn signal wire to red wire, then I added a ring terminal to the original ground wire that was big enough to fit around the mounting stud. That allows me to have run/turn in the rear for more visibility and in my state it is legal as long as the lenses are red.

Here's a pic:


The yellow wires are spliced into the running light for the brake.
The green wires are going to the original turn signal wires.
And you can see my ring terminals for ground.

Easier to do with the light off of the bike, but I initially wired it on the bike. Just took it off to route the wires in a manner I was more comfortable with. I also solder and shrink wrap everything, and used the original 2 pin connectors, but butt-connectors would work. I just don't like wires turning green.
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Old 04-21-2014, 12:08 PM   #9 (permalink)
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Thank you for*good*communication.
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Old 04-21-2014, 12:15 PM   #10 (permalink)
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