How to fix your Ignition Switch - Page 2 - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #11 of 149 (permalink) Old 10-08-2007, 10:11 PM Thread Starter
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Quote:
Originally Posted by 472viper
LOL, no get this, the M50 was hit so hard that the key side of the ignition switch cracked almost in two. I have another switch assembly, but as you said I will have to remove the the keyset from the cracked set and install it in the replacement so the ignition and gas cap are still keyed alike.
Viper
Once you remove the 2 little screws on the key side, there is only 4 parts.

The lock cylinder, a spring, a cylinder cover, and main cover.

Here is the cylinder...


Here is the spring inside the switch. Carefull, as it can just fall out. If you have a problem getting the cyclinder back in with the spring, put a dab of grease in the end of the cylinder. It will hold the spring for you. I used the bulb grease. The spring goes over the rod inside there that turns.


Then the 2 covers.


Hope this helps.
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post #12 of 149 (permalink) Old 08-06-2008, 10:24 AM
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DAMN I wish I would have seen this a while back. I ended up buying a whole new lock set (used, at least) because my ignition switch went bad out in Sturgis. Stopped me dead. I don't remember, but I don't think I had any lights or anything. Thankfully Cobra and JJ got me wired up to get me home, but I ended up buying the parts.

As for the recall, it wasnt covered on the 03's anyway.

Got to mark this for the next time it happens. Thanks for the great details.

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post #13 of 149 (permalink) Old 09-02-2008, 12:08 AM
 
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Subscribed and you were right on the money. I only wished I hadn't pulled the whole switch off the bike first cause it's a ***** to get off, god only knows how long it'll me take to get it back on...LOL
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post #14 of 149 (permalink) Old 09-02-2008, 06:57 AM
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Many Thanks harryp for thinking of everyone else. I haven't had this problem (yet), but I'm saving this info for future reference.

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post #15 of 149 (permalink) Old 09-03-2008, 08:56 AM
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Iginition switch

My C50 failed to start on a Sunday, 70 miles from home ,in a area that doesn't have cell phone reception. After a couple hours of checking all possibilities and pushing the starter button, the starter motor finally kicked in. I drove it home with stopping. When I got home the starter worked intermittently. I took the bike to the dealer and the problem couldn't be replicated. It worked fine. Several months later the starter motor was dead again...fortunately while I was at a friends house, about nine miles from the dealer. The dealer sent a truck over to pick up the bike. They found the problem the next day and replaced the ignition switch under the extended warranty. The dealer described the copper contact sticking exactly as you presented in your pictures. Nice job on documenting the fix!
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post #16 of 149 (permalink) Old 09-05-2008, 07:55 AM
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Year Bike

Is this recall only on C-50's or Volusia's too?


2003 Suzuki Volusia VL800-64,000 Miles and still going-(01/04 - 04/12) SOLD!!
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post #17 of 149 (permalink) Old 09-05-2008, 12:46 PM
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Its not on the 2003's as far as I know. I tried that and got nowhere so I am guessing its only the C50's. Also, I believe the recall is only on a wiring issue (may include a harness) but its not for the switch.

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post #18 of 149 (permalink) Old 09-05-2008, 01:21 PM
 
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Recall is only for the way the wiring harness is ran and not for the actual switch...
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post #19 of 149 (permalink) Old 09-19-2008, 12:11 PM
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Re: Iginition switch

Quote:
Originally Posted by Raygun
My C50 failed to start on a Sunday, 70 miles from home ,in a area that doesn't have cell phone reception. After a couple hours of checking all possibilities and pushing the starter button, the starter motor finally kicked in. I drove it home with stopping. When I got home the starter worked intermittently. I took the bike to the dealer and the problem couldn't be replicated. It worked fine. Several months later the starter motor was dead again...fortunately while I was at a friends house, about nine miles from the dealer. The dealer sent a truck over to pick up the bike. They found the problem the next day and replaced the ignition switch under the extended warranty. The dealer described the copper contact sticking exactly as you presented in your pictures. Nice job on documenting the fix!
Would your bike crank at all when you had this problem? I'm having it on my c90 and it will crank but it's getting no spark. I'm going to try cleaning the iginition switch tonight and see if it helps. everything else seems to check out.
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post #20 of 149 (permalink) Old 09-19-2008, 02:17 PM
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When my ignition switch went out this week, nothing would happen when it turned the key on...no headlights...no dash lites...only taillight and turn signals worked.

It's in the shop now for its replacement under extended warranty coverage.

Jeff
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