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Get a genuine Suzuki ignition switch. The aftermarket Chinese ones are garbage. I bought one off ebay since I too didn't have a key. When I installed it and turned the bike on it blew the main fuse. The POS was wired all sorts of wrong. I thought about trying to rewire it but decided it wasn't worth the effort for such a crappy switch. I ended up taking the original ignition lock to a locksmith who was able to make a new key for it in about 30 minutes.
I would put money on your ignition switch being the source of all the problems.
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2003 Suzuki GZ250 (Sold)
1986 Suzuki Cavalcade LXE
1986 Suzuki Intruder VS700
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