Question about 2004 Suzuki VL 800 Volusia

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Need to replace ignition switch on '01 Volusia...where to find one..?

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Your bike is new enough the dealer should be able to get one for you. You may want to save some bucks and get one used on the web. GOOGLE " motorcycle salvage suzuki " You can probably get one there. Worst case you get one without a key then have a locksmith make a key for it.

Please rate this answer. Thanks bobbyd429!

Posted on Apr 17, 2009

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Posted on Jan 02, 2017

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I have a 2003 Suzuki Volusia that blows the 15 amp ignition fuse randomly.Can go weeks without a problem then it will blow. I replace it and it is fine or other times it blows repeatedly.


Wendy, Check the starters wiring circuit for a pinched/bare/damaged wire. Check the attached links,instruction and guides,good info. to trouble shoot your problem. Good luck
"I hope this helped you out, if so let me know by pressing the helpful button. Check out some of my other posts if you need more tips and info."
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Jun 24, 2016 | 2003 Suzuki VL 800 Volusia

2 Answers

How do i fixe a loss of power and cut outs when bike is hot ?


Hi, David the following applies to carbureted also fuel injected models and the usual suspects are:
1. Severely discharged or a damaged battery, 9 volts or lower.
2. Failed alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Failed main circuit breaker or ignition switch, check for loose connections and continuity.
5. Failed system and or ignition relay, check for continuity.
6. Failed ignition coil, ignition/electronic module.
7. Failed CKP, CPS, CMP, MAP, TPS, or BAS sensor, corroded, loose or broken wire connector pins/sockets.
8. Throttle cables and or idle speed improperly adjusted hot idle speed should be 950 RPM to 1000 RPM.
9. Air/fuel mixture ***** improperly adjusted.
10. Water or dirt in the fuel system, carburetor or filter.
11. Restricted, blocked or kinked fuel line.
12. Fuel tank empty.
13. Gas cap is not venting properly or fuel tank venting system blocked.
14. A failed fuel pump, pressure regulator and or fuel injectors.
15. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
16. Needle and seat stuck closed in the float bowl.
For more information about your issue and valuable "FREE" downloads that you need please visit the websites below. Good luck and have a nice day.
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Mar 13, 2016 | 2002 Suzuki VL 800 Volusia

1 Answer

Neutral light does not always go on when out of gear


Hi, Colin you may have a neutral switch issue or a neutral light connection problem for more information about your issue and free downloads that you will need please visit the websites below. Good luck and have a nice day.
Neutral light not on while in Suzuki Volusia Forums Intruder Volusia Neutral Safety Switch Repair Instructions with pics Sportbikes net
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Jan 16, 2016 | Suzuki VL 800 Volusia Motorcycles

1 Answer

Where do you fill and drain the gear box for a Suzuki Volusia intruder 2002 800


I figure that engine and gearbox use the same oil filling; but check the following:
  1. Need 2002 Suzuki Volusia 800 Owners Manual - Suzuki ...

    www.volusiariders.com/.../186127-need-2002-suzuki-volusia-800-owne... Apr 26, 2009 - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum ... Thanked 0 Times in 0 Posts. Need 2002 Suzuki Volusia 800 Owners Manual ...

Apr 28, 2015 | Suzuki Motorcycles

1 Answer

2003 suzuki volusia has power but when hit start goes dead


short in ignition switch- common in these bikes.. check it carefully

Jul 13, 2014 | 2003 Suzuki VL 800 Volusia

1 Answer

Ignition switch burned out Key was getting very hot


the that is burned is connected to the ignition switch, and it may be is the cause of the problem of your vehicle .

Jul 22, 2009 | 2004 Suzuki VL 800 Volusia

1 Answer

How do you check the water level in a 2001 suzuki volusia 800?


peterbiltcoh,

If you haven't gotten an answer yet, here's how to check the coolant level in your '01 Volusia. The coolant tank is located on the bottom left side of the engine. There is a sight slot cut in the cover that will allow you to view the level. I preferr to take the cover off (3 screws) to make sure I'm seeing the marks on the coolant tank and to check the color of the coolant. It's an easy check even with taking the covers off (about 15 minutes). If the coolant is low, or discolored, you can make the necessary adjustments.

Jul 01, 2009 | 2004 Suzuki VL 800 Volusia

1 Answer

Nothing happens turn the key and nothing I charged the battery and still nothing 2003 volusia


Hi and welcome to the site,

Almost always, your desribed problem indicates a blown main fuse. The main fuse holder is usually integrated with the starter motor relay. To locate this relay, follow the big cable from the battery's + terminal.

Others to check would be the battery cables and the harness / connector leading to the ignition switch.

Would appreciate updates.

Good luck and thank you for using FixYa.

Jun 23, 2009 | 2003 Suzuki VL 800 Volusia

1 Answer

800 volusia suzuki


You will have to remove the ignition with some security bits.

Jun 23, 2009 | 2003 Suzuki VL 800 Volusia

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