2003-2004 IGNITION SWITCH RECALL

[bernabeu]

As per the NHTSA and SUZUKI RECALL NO. 2082:

ALL 2003 models are affected

2004/400: through *42101092
2004/650: through *42101022

required replacement part: Kit # 99103-11199
(the proper replacement switch terminal case can be identified by a black line on the coupler case)

dealer should have special tool (PN 99103-11200) on hand (free from Suzuki) as well as the TSB (GV/AN Bulletin No. 20 - 9/1/2005)

UNLESS YOU PERSONALLY KNOW THE ORIGINAL IGNITION SWITCH WAS NEVER (I MEAN NEVER, EVER) PLACED BETWEEN OFF AND ON ACCIDENTALLY THE BIKE IS NOT SAFE TO RIDE UNTILL IT IS REPLACED

[apleschu]

Any idea what the problem is?

[Selias]

A search for 'ignition recall' (all words) will result in quite a bit of posts on this. Look HERE (newer summary of THIS THREAD) for some good info on the problem and why there is a recall.
Here are vfdcaptain's AWESOME photos which will give you a better idea of why there is a recall... http://burgmanusa.com/gallery/album89
here's a thumbnail off page two:

And this is a GOOD example of why these BUSA forums are such a great thing! Thanks to vfdcaptain (and I believe others) we knew about this problem before just about anyone and I personally believe members of this forum were instrumental in this particular recall being issued (at least in the USA)?

In essence the problem with the ignition switch (as I understand it) is not having the switch all the way ON has created a 'shorting'/overheating problem on older models (2003 and part of 2004) which can create an unsafe driving condition or prevent ignition switch usage. Definately worth have the recall done if your model is one of the ones listed in the recall!

[Brian]

Any idea what the problem is?

As Selias said.

One of the contacts in the switch was too small on the early 250s, 400s, and 650s, and if the key was not turned completely on there could be arcing with possible meltdown.

Even if the key was turned all the way to start, vibration or a bump of the knee could nudge it off the detent.

The biggest problem was that engine power and all lights could suddenly quit without warning. Not a good thing if you're hard into a turn in the middle of the night.

[pirmil]

just info
http://www.suzuki.co.jp/cpd/koho_j/recall/050823.htm

[dcook8222]

I took my 2003 AN650 to the dealer and they performed the ignition switch replacement under the recall. Then starting a week later the ignition was cutting out while running and I was getting the F1 error lights when trying to start it. I took it back to the dealer and the "dealer mode" diagnostic pointed to the ignition switch not getting proper power to the computer module.

The mechanic discovered that when the ignition switch overheated it warped the plug that mates to the back of the ignition switch. Suzuki does not sell the plug -- the solution replace the entire wiring harness. Then Suzuki informs me the wiring harness is backordered for three weeks! I assume I am not the only one with this issue.

If you have the recall performed, get the dealer to check the plug for the back of the ignition switch, for heat damage.

In an attempt to get my Burger on the road I am looking at finding a wiring harness through salvage channels. If you have any resources let me know.

[Brewman]

Would the recall or any kind of warranty pay for the wiring harness or it's installation? That could get rather expensive, I'd imagine.

[dcook8222]

Suzuki said they will pay for the wiring harness. It is a result of the recall ignition switch failure on my Burgman 650. I do hate to have the scooter in the shop for 3-weeks!

[Sails]

There is a Canadian recall as well. I emailed Suzuki Canada with my VIN and got a reply that told me to call my dealer.
Interesting, I just put my bike into storage for the winter, I guess I will have to call and see if I can do it in the spring or whether I have to pull the bike out.
Knowing my luck it'll be at the dealer and we will get 3 feet of snow!

[dcook8222]

Ken, I would check with your dealer. Usually there is a window in which a recall can be applied. As far as putting up my Burgman for the winter ... I'm in Houston and can ride year-round. I am just putting up my bike for the recall.

[Sails]

Ken, As far as putting up my Burgman for the winter ... I'm in Houston and can ride year-round. I am just putting up my bike for the recall.

Nothing personal,
I hate you!
I hate you!
I hate you!