Question about 2004 Suzuki VL 800 Volusia

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Ignition switch burned out Key was getting very hot

After not starting idecided2check the wireing i found that in the
headlinght assembly that there was an unused attachment that
was burned to a crisp at the end. I figure that this was causing
a short in the ignition switch and made it burn out. I wont
know for sure untill i get a new one to put in. It is very easy to
replace had to buy a star kit though to get the bolts out.
I am hopeing that this was the reason anyway.
wondering if this is a current problem with all volusias

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

Posted on Jul 22, 2009

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Don't believe it would be the ignition switch. It sounds like the starter relay may be stuck in the on position. Find the starter relay and pull it out. One terminal would be hot at all times-use a test light grounded to engine block and probe the relay terminals. Should only have one terminal showing power. Now have someone hold the key in start position. Now you should have two terminals showing power, and when key is released to the run position, the second hot terminal should stop showing power.
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What is the cable connected to the ignition that controls the dash board's gadgets


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Wiring diagrams are almost always found in repair manuals. Check if your library has a manual for your car. Most libraries have quite a few repair manuals. Or parts stores sell repair manuals too, for about $25. Try to find a Haynes repair manual for your car. The other popular repair manual is from Chilton. My preference is Haynes, just my preference. I been burned by Chilton manuals sooo many times-incomplete wiring diagrams, incorrect information, incomplete information. Haynes are not perfect by any means, you want perfection-spend big bucks for a factory service manual ! In general, Haynes is more complete than Chilton.
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