Suzuki VL800 problems & recalls

Problem: Suzuki is recalling certain model year 2008 through 2010 motorcycles manufactured from july 2007 through september 2009, equipped with regulator/rectifier assemblies, suzuki part numbers 32800-41f11, 32800-15h10, 32800-05h11, 32800-41g10, 32800-15h00, 32800-18h00, 32800-05g10, 32800-10g10, 32800-05h20, or 32800-06g01. some regulator/rectifier assemblies were produced with insufficient adhesion between the power module (circuit board) and the rectifier case that contains a heat sink to dissipate heat. due to insufficient adhesion, heat generated on the power module circuit board can cause the circuit board to deform, and lift of the case.

Risk: This condition causes excessive heat on the circuit board and uncontrolled electric current output, which can result in insufficient charging current being provided to the motorcycle battery. this can cause discharge of the battery and can lead to engine stalling and/or a no-start condition. engine stalling while riding can increase the risk of a crash.

Fix: Suzuki will notify owners and suzuki distributors will replace the regulator/rectifier with an improved part free of charge. the safety recall began on march 2, 2011. owners may contact suzuki at 1-714-572-1490.

Problem: 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.

Risk: 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.

Fix: 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.