2003 Suzuki VL 800 Volusia Logo

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Posted on Jun 23, 2009
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800 volusia suzuki

Have a 800 suzuki had key in and on lock position some one turn wheel and shear the lock tried to pull key switch will not come out

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Ed Nelson

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  • Expert 149 Answers
  • Posted on Nov 04, 2010
Ed Nelson
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Joined: Nov 04, 2010
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You will have to remove the ignition with some security bits.

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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:
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2003 suzuki volusia has power but when hit start goes dead

short in ignition switch- common in these bikes.. check it carefully
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Lost keys to my 2002 zuzuki volusia, where do i find key code and how do i get to it]

bike serial number(from the dealer)
or remove switch and take to lock smith
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Key wont turn

bad key or bad key cylinder. first look for damage to the key. if there isn't any, try lubricating the lock cylinder with powdered graphite.
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When i go to crank my bike my key want turn to start my bike

Are you certain you have the correct key and it is inserted properly? If yes to both, you might try cleaning the lock with a little WD-40. If that doesnt work your alternatives are (1) call a lock smith (2) replace the switch.
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Taillight/brake light stays on with key turned off?

When you turn the key off in the ignition, there are three positions. Off, Off/steering locked, and then off/steering locked/tail light on. Might make sure you aren't turning the key all the way to the third position.
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Ignition switch 2002 Suzuki VL 800 Volusia

How to Replace a Car Ignition Switch

What You'll Need
If you are facing problems with ignition start, then the time has come to replace the car ignition switch. An ignition switch is located on the dashboard or the steering column of the car. It serves various functions such as activating the starter and the ignition system. It also routes the current to various car accessories like the radio, music system, door control mechanisms and lighting system. Problems with an ignition switch lead to a host of other problems like being unable to start the car, inability to start the music system, and others. Here are some pointers if you need to replace your ignition switch.

Step 1 - Remove the Steering Column
Disconnect the battery cable from the battery terminal. Next, disconnect the steering column by taking out the screws. Remove and pry the fasteners off as well. This can be done with the help of a screwdriver or a socket wrench.

Step 2 - Detach the Wiring
steering wheel

Remove the wiring harness which connects itself to the ignition switch. It is located on top of the steering column. Disconnect the horn wire and remove the nuts and washers. Detach the wiper of the windshield and turn off the signal switches. Finally disconnect the wiring.

Step 3 - Test the Switch
Examine the ignition switch. This is done with the help of a test light. The test light glows when the key is in the start position. With the key in the off position, the test light should not glow. If the ignition switch works fine, the output on the test light would indicate so.

Step 4 - Install the New Switch
Detach the nuts or screws which hold the steering column and the ignition switch. Use a screwdriver or a socket wrench for accomplishing this task. Remove the faulty old switch and replace it with a new one.

Turn off the ignition switch and insert your key in the switch. Free the cylinder by depressing the retaining pin. Get the key again to the lock point and take out the key. Ensure that all the holes are lined up properly. If this is not the case, then the switch will not be properly installed with fasteners.

Step 5 - Secure the New Switch
Screw and bolt the new switch to the steering column with help of a fastener. Attach the wiring and the steering column back to its normal position. Replace and restore the housing with fasteners again. Ensure that the cylinder and assembly are properly aligned. Reattach the various switches and the mounting screws.

To replace a car ignition switch is not easy, especially in the newer cars. These cars are installed with devices such as the anti-theft which makes the task more challenging. Refer to the manual for pointers on working with such anti-theft devices.
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Starter turns but will not start, can smell fuel

sounds like it flooded hold it wide open and start it
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Key won't turn out of the lock position

Check your key to make sure none of the teeth have sheared off. Try using the second key to start it.
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