I HAVE 2 2005 SUZUKI C50 BOULEVARDS MOTORCYCLES. I ADDED A LIGHT BAR MADE BY SUZUKI. IT ATTACHES ELECTRICALLY TO A PLUG PROVIDED BY SUZUKI INSIDE THE HEADLIGHT CAN. WHEN USED, IT OVERLOADS THE IGNITION SWITCH, CAUSING HEAT, MELTING PLASTIC INSIDE. THIS IS NOT A PROBLEM ON THE 2004'S (VL800 VULSIA) WHICH RUN OFF A CARBURETOR. THE…
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I HAVE 2 2005 SUZUKI C50 BOULEVARDS MOTORCYCLES. I ADDED A LIGHT BAR MADE BY SUZUKI. IT ATTACHES ELECTRICALLY TO A PLUG PROVIDED BY SUZUKI INSIDE THE HEADLIGHT CAN. WHEN USED, IT OVERLOADS THE IGNITION SWITCH, CAUSING HEAT, MELTING PLASTIC INSIDE. THIS IS NOT A PROBLEM ON THE 2004'S (VL800 VULSIA) WHICH RUN OFF A CARBURETOR. THE 2005'S ARE FUEL INJECTED, AND REQUIRE A FUEL PUMP. I BELIEVE THE IGNITION SWITCH IS THE SAME ON BOTH. THOSE THAT HAVE THE LIGHT BAR ON THE 2004'S AND EARLIER DO NOT REPORT THIS PROBLEM. THOSE WITH 2005 AND UP, DO REPORT THIS PROBLEM. REFERENCE VOLUSIARIDERS.COM, AND SEARCH ON IGNITION SWITCH. IT DOES NOT APPEAR THAT THE 2005'S ARE DESIGNED TO HANDLE THE ADDITIONAL LOAD OF THE FUEL PUMP AND THE LIGHT BAR. THE SWITCH CAN FAIL WHILE IN OPERATION, AND LOSS OF POWER CAN CAUSE AN ACCIDENT. I CAN RESEARCH THE FAILURE DATE, BELOW IS A GUESS. THE REPAIR REQUIRES THE INSTALLATION OF A RELAY, USING THE HEADLIGHT WIRE TO TRIGGER THE RELAY. THE POWER IS FED FROM THE BATTERY, NOT THE PLUG IN THE HEADLIGHT CAN FURNISHED BY SUZUKI. *TR
ON CERTAIN MOTORCYCLES, THE IGNITION SWITCH WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED AT THE TIME OF PRODUCTION. IF THE WIRING HARNESS IS NOT ROUTED PROPERLY, IT CAN RUB AGAINST THE CLUTCH CABLE/THROTTLE CABLE.
Consequence & remedy
Consequence: CONTINUED RUBBING MAY EVENTUALLY LEAD TO A SHORT CIRCUIT WHICH MAY CAUSE THE ENGINE TO STALL OR THE LIGHTS TO GO OUT. THIS WILL INCREASE THE CHANCE OF A CRASH RESULTING IN SERIOUS INJURY OR DEATH.
Remedy: DEALERS WILL RE-ROUTE THE IGNITION SWITCH WIRING HARNESS AND REPLACE THE LOCK SET INCLUDING THE IGNITION SWITCH ALONG WITH THE CLUTCH CABLE/THROTTLE CABLE FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 6, 2006. OWNERS MAY CONTACT SUZUKI AT 714-572-1490.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
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No exact-year investigations in this snapshot.
2005 Suzuki VL800 Problems, Complaints & Recalls | Skip That Year