How to fix your Ignition Switch - Page 3 - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
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post #21 of 149 (permalink) Old 09-21-2008, 09:28 AM
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Re: How to fix your Ignition Switch

Harry, Nice work. I had my switch replaced, and the bike has either run right or died shortly after starting. I can cycle the key, and get it to run right. May take several trys though. I checked the wiring diagram, and it showed all wires common with key on. I checked mine, and the Orange/yellow was not common. I checked my other bike, and it was not common there either. I am convinced it is the switch. Both have light bars, both are 2005 C50 (one CA the other is other 49). I put the light bars on a relay and used a headlight wire, instead of the Auxiliary, to fire it, so the lights would go out during starting. Next time you have the tank off, would you mind ohming your switch out and tell me what you see? Do you have a light bar? I think Suzuki did not beef up the switch when they wen to Fuel Injection, and the light bar overloads the switch, melting the plastic, as you note. Thanks, Richard
I have a used switch and no key. I wanted to ohm it out also, can't get the barrell out. Is there a trick to it?

Best Regards,
Richard
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post #22 of 149 (permalink) Old 10-03-2008, 10:20 AM
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post #23 of 149 (permalink) Old 07-02-2009, 10:16 PM
 
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Harryp,

That fix was the ticket. I rolled out my garage last week looking to fire the bike up for a quick ride, but had no instrument gauge or headlight. The taillight was on and turn signals worked. A search on this site got me to this subject and I was on my way. I was able to knock the fix out in under an hour thanks to your instructions and pictures.

I have OEM light bar which apparently put the extra load on the ignition switch. The plastic was slightly melted which prevented the tabs from moving up and down freely in the white cross shaped thing. Suzuki should know better

It works fine now, but I would have to consider the fix temporary, as I would hate to get stranded miles away from home. I might have to bite the bullet and purchase a new ignition switch. All for a small plastic part that probably cost a buck or two to manufacture.

Again thanks. You saved the day!
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post #24 of 149 (permalink) Old 08-31-2009, 09:45 AM
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I think the main reason the ignition switch gets fried (melted) is because of the engine heat.

Test it yourself:
1. Ride at highway speeds for more than 1 hour, while riding you can put your hand in front of the space on the left hand neck cover. You'll notice a lot of heat.
2. After the hour, stop at a gas station, rest, put some gas in your tank... but check under the left neck cover. You'll notice a lot of heat emanating from the engine up to the neck of the bike. In fact, you can touch the frame there, and it will be hot.

I surmise that the heat from the engine is flowing up the neck and melting electrical components there. No wonder some motorcycles don't have neck covers! It's a way of dissipating the heat.

2006 Suzuki C50T. All OEM.
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post #25 of 149 (permalink) Old 08-31-2009, 11:28 AM
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Looks like I am going to have to give this a try. I am now having problems with a second switch. I replaced it the first time back in 2006 so I am getting 3 years out each switch. This is ridiculous!! Been riding for almost 30 years and never had a problem like this. Now its happened twice already. I'm getting to the point where I dont trust my bike to take it on a long trip.

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post #26 of 149 (permalink) Old 08-31-2009, 01:14 PM
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Quote:
Originally Posted by SiouxperKev
Looks like I am going to have to give this a try. I am now having problems with a second switch. I replaced it the first time back in 2006 so I am getting 3 years out each switch. This is ridiculous!! Been riding for almost 30 years and never had a problem like this. Now its happened twice already. I'm getting to the point where I dont trust my bike to take it on a long trip.
Maybe this is the place to post this:
On long rides (longer than 1 hour) at interstate speeds, I've noticed the following odd behavior with my stock OEM C50T 2006:

1. I'll stop and rest at a gas station; fill up the tank; use the rest room; check out the energy drink they have on hand; then hop back on the bike.
2. What's odd is when I hit the ignition switch, my bike will have a hard time turning over. Sometimes I have to add throttle to it.
3. Why's it difficult to start during a long ride?

Thank you.

2006 Suzuki C50T. All OEM.
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post #27 of 149 (permalink) Old 08-31-2009, 02:16 PM
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Quote:
Originally Posted by Trent
Quote:
Originally Posted by SiouxperKev
Looks like I am going to have to give this a try. I am now having problems with a second switch. I replaced it the first time back in 2006 so I am getting 3 years out each switch. This is ridiculous!! Been riding for almost 30 years and never had a problem like this. Now its happened twice already. I'm getting to the point where I dont trust my bike to take it on a long trip.
Maybe this is the place to post this:
On long rides (longer than 1 hour) at interstate speeds, I've noticed the following odd behavior with my stock OEM C50T 2006:

1. I'll stop and rest at a gas station; fill up the tank; use the rest room; check out the energy drink they have on hand; then hop back on the bike.
2. What's odd is when I hit the ignition switch, my bike will have a hard time turning over. Sometimes I have to add throttle to it.
3. Why's it difficult to start during a long ride?

Thank you.
Trent:

No idea what's up there. Might want to start a new thread so some others will see it and maybe have an answer. Good Luck.

Let's Ride!!
2003 40th Anniversary Volusia

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post #28 of 149 (permalink) Old 09-02-2009, 03:45 PM
 
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Helpful information that I could have used earlier. Hereís my experience which I took up the line to Suzuki USA. In the end it was a complete waste of time but valuable lesson learned about how Suzuki stands behind their products.

Background: Turn ignition switch on, turn signals would work but not the fuel pump, headlights etc. Problem was sporadic, hard to replicate. Originally thought it might be an ignition problem per recall but VIN was just outside the recall range. Finally able to replicate it at the dealer who (like I) concluded it was the ignition switch. Bike had 7,000 miles but now out of warranty.

Action: Suzuki repair shop had a 2 week wait so took it to an independent shop (and master mechanic that teaches motorcycle electrical systems at the community college) who replaced the ignition switch. Problem solved. Reason for failure? Three of the four wires in the wire harness were longer than the main orange wire putting constant tension on the orange wire to fail at the quick connect and the ignition switch. The three wires had been spliced by the manufacturer. Pictures show it quite clearly. Confirmed disconnect with ohm meter. It was bound to fail the only question was when. Took high resolution pictures and wrote a letter to Suzuki USA in Brea, CA illustrating how it was manufactured defectively from the beginning. No response, not even acknowledgement of receipt of the letter. After six weeks called Suzuki got a customer representative trained to say that he too was a motorcycle enthusiast and it must have been me, given that it happened out of warranty. Thatís code for Suzuki could care less. Offered to send the part and they could do their own inspection. Donít bother.

Lesson learned: When these type of problems occur is when you really find out what manufacturerís really stand behind. In this case, not much. Sold the bike, bought another brand which has exceeded my expectations and resolved to never own anything Suzuki again.
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post #29 of 149 (permalink) Old 09-02-2009, 07:50 PM
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Quote:
Originally Posted by SiouxperKev
Quote:
Originally Posted by Trent
Quote:
Originally Posted by SiouxperKev
Looks like I am going to have to give this a try. I am now having problems with a second switch. I replaced it the first time back in 2006 so I am getting 3 years out each switch. This is ridiculous!! Been riding for almost 30 years and never had a problem like this. Now its happened twice already. I'm getting to the point where I dont trust my bike to take it on a long trip.
Maybe this is the place to post this:
On long rides (longer than 1 hour) at interstate speeds, I've noticed the following odd behavior with my stock OEM C50T 2006:

1. I'll stop and rest at a gas station; fill up the tank; use the rest room; check out the energy drink they have on hand; then hop back on the bike.
2. What's odd is when I hit the ignition switch, my bike will have a hard time turning over. Sometimes I have to add throttle to it.
3. Why's it difficult to start during a long ride?

Thank you.
Trent:

No idea what's up there. Might want to start a new thread so some others will see it and maybe have an answer. Good Luck.
Thanks for the advice...I've set up another thread.

2006 Suzuki C50T. All OEM.
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post #30 of 149 (permalink) Old 09-02-2009, 08:18 PM
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Quote:
Originally Posted by 5540Tim
Helpful information that I could have used earlier. Hereís my experience which I took up the line to Suzuki USA. In the end it was a complete waste of time but valuable lesson learned about how Suzuki stands behind their products.

Background: Turn ignition switch on, turn signals would work but not the fuel pump, headlights etc. Problem was sporadic, hard to replicate. Originally thought it might be an ignition problem per recall but VIN was just outside the recall range. Finally able to replicate it at the dealer who (like I) concluded it was the ignition switch. Bike had 7,000 miles but now out of warranty.

Action: Suzuki repair shop had a 2 week wait so took it to an independent shop (and master mechanic that teaches motorcycle electrical systems at the community college) who replaced the ignition switch. Problem solved. Reason for failure? Three of the four wires in the wire harness were longer than the main orange wire putting constant tension on the orange wire to fail at the quick connect and the ignition switch. The three wires had been spliced by the manufacturer. Pictures show it quite clearly. Confirmed disconnect with ohm meter. It was bound to fail the only question was when. Took high resolution pictures and wrote a letter to Suzuki USA in Brea, CA illustrating how it was manufactured defectively from the beginning. No response, not even acknowledgement of receipt of the letter. After six weeks called Suzuki got a customer representative trained to say that he too was a motorcycle enthusiast and it must have been me, given that it happened out of warranty. Thatís code for Suzuki could care less. Offered to send the part and they could do their own inspection. Donít bother.

Lesson learned: When these type of problems occur is when you really find out what manufacturerís really stand behind. In this case, not much. Sold the bike, bought another brand which has exceeded my expectations and resolved to never own anything Suzuki again.
Dude, I feel your pain. I really do. I'm feeling like I got jipped with Suzuki. I even called their customer service just now to ask a question about their recall. They said they closed at 5 PM PST, and I called them at 4:45 PM!!!
How do they get to leave early?
Anyways...I guess I got what I paid for...
Any suggestions on a bigger bike, that's not a suzuki; something that comes with better customer support, and a company that cares about the quality of their bikes (non HD)? Maybe Yamaha or Honda or Kawasaki? The Kawa Vulcan 900 Classic LT? The Nomad riders are fanatical about their bikes...
j/k...i'll like my zook 4 now

2006 Suzuki C50T. All OEM.
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