I found this on an old Suzuki Volusia forums and I haven't seen anyone post a video on how to do this. this is the written text of that post:

To determine first if this is your problem, when you turn the key on, the brake light is on, the blinkers work, but nothing else does, NOTHING else does. :)

1. Go buy a set of SECURITY TORX bits. These are regular torx bits, but have a hole in the middle. You have to have these first. Preferably, do not get the ones shaped like an allen wrench. Get the ones that you can put on a 1/4 inch extention and ratchet, or a T_Handle set. The specific Torx bit you need is a T-20. Also buy some of that bulb grease while you are there, the kind for light bulbs on a car.

2. Remove drivers seat. If you still have the pillion on, you also have to remove it first. Once the seat is off, remove the 30 AMP main fuse. It is under a plastic cover close to the tank. If you don't remove this fuse, you will blow it when putting the switch back together.

3. Remove gas tank. You do not have to take it off the bike. You can remove the bolt where the front of the seat is, then slide it back. Just pick the back up a little and pull back. Make sure it is sitting solid so it will not fall of the bike. This is about how far I pulled my tank back

4. Remove the black plastic neck cover opposite the key side. It just pops off. Pull at the bottom then from the top. You will see a metal rod. Maybe an 1/8" in diameter. The top part has a bolt that holds it to the frame. The bottom part just slides into a hole on tab welded to the frame.

5. Now you will see the electrical plug for the switch. Mine is green. You will need to unplug this.

6. Now you will see the back of the iginiton switch. There are are 2 little torx head screws that hold it on. You will have to hold the cables out of the way to remove the screws, as the cables are in the way. Be really carefull when removing these screws, they are small and like to drop into funny nooks and crannies

7. Now you will see a white cross shaped piece of plastic with 2 chrome balls on it. Remove this, it just pulls out, really easy.

8. Here are the spring loaded copper tabs.

These need to go up and down real easy when you press them down. Sometimes they just get stuck down from maybe being "dry". Mine was stuck down because the plastic was a little melted from to much load on the electrical part. I'm thinking maybe my spot lights might be pulling to much juice. So I put them on a switch.

9. Now put some of that grease on these tabs and work it in. Also, spread some grease on the little copper pods in the switch. This black piece just slides out also. If you turn it over, you will see the little resistor there that gives people problems when they try to place an after market switch on their bike.

10. Now also put some of that grease inside the little cover you pull pulled off. You will see some indentions in there. This is what the 2 little balls on the white piece rotate on. These cause the little bumps you feel when you turn the key.

11. Now put the black piece back in. It only can go in one way. Now slide the white piece back on the shaft. If you look at the end of shaft, you will see is is cross shaped. Look at the end and put the white piece on. One side is thick, one side is narrow. Hard to explain, just look. Match up the hole design in the white piece with the same design at the rod coming out.

12. Now put the cover back on and replace those small screws. Be carefull not to drop them. Just snug these screws up. They are cheap metal and will strip if over tightened.

13. Now replug the electrical connection, replace the 30 amp fuse and turn the key. Everything should work now. If it doesn't work, first check the fuse. If it still doesn't work, pull the fuse, then pull the cover off the switch again and make sure everything is ok. But it should work.

14. Now replace that little metal rod, the plactic neck cover. Then slide the tank back up and rebolt it. Replace you seat(s), start the bike and ride!!

Hope this is able to help some people here.

свернуть