2002 suzuki intruder3/22/2023 The problem often comes and goes, so the bike may suddenly fire right up, making you think the problem is solved, only to reappear days or weeks later. If you do not want to tackle it yourself a shop will charge you $150 or so to put it on. The Clymer and Suzuki shop manuals say you need a special tool to remove the old one, but that is because it is so easy to damage the old one, obviously of no concern if you are tossing it in the trash and putting on a new one. Not hard to put in at all: drain the oil, take off the left side cover, undo three bolts to remove the old one, slip on the new one, feed the wire harness the same way as the old one and plug it into the main harness, put the cover on with a new gasket, refill the oil. You can get a Suzuki OEM assembly for about $330 (the original flawed one is no longer available, so the redesigned model is the only one they sell) or an aftermarket one for about $180. Suzuki completely redesigned the assembly in 2005 to solve the problem, so they know darn well the original one was flawed- but because it was never a safety issue, they did not have to recall the bikes and fix them for free. It all stems from a very poorly designed stator/ signal generator/ wire harness assembly, and I have seen dozens of 1998-2004s need this assembly replaced. These electrical demons have driven more than one Intruder 1500LC owner bonkers, and have trashed the reputation of an otherwise fine bike. Sometimes you can jump start the bike and it will fire right up, sometimes if you just let it sit it will fire right up, other times no matter what you do it will not start. The bike acts liek the battery is dead, or the battery will drain suddenly, or the bike will turn over but not spark. Intruder 1500LCs from this time period are notorious for this sort of starting problem.
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