Ronzo

Harryp. Thanks for the great illustrated and informative description for ignition switch problem repair.

Oklahoma_mike

So I am having this issue right now. Bike acts like dead battery so lights or anything 30amp fuse is fine and if I jump the starter solenoid she will crank. She broke down in a restaurant parking lot so I got a ride and will be running home to get some tools and give this a try. I will let you know if this doesn't fix it and update with the resolution. Thanks for posting this repair!!!

Oklahoma_mike

This wasn't the issue on my bike. Mine had an issue with one of the pins inside the green connector. It looked as though it got a little too hot.

will do

harryp, thanks so much for you detailed post about the switch repair had to fix one to night for a friend and this was spot on. Due to you detailed post the repair took only thirty minutes to fix and had his back on the road.

13thman

Wooohoooo! this fixed my ride!
No signs of heat but the contacts on the black pad looked faded so I hit then with some fine sandpaper put the lube on and slapped it back together.

2moro I'll put in the relay for the light bar just to be safe and while i have the tank off I want to swap out the coolant.

Thank so much harryp for the very helpful post!

volusiaphil

You just saved me alot of heartache thanks

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suncowiam

i opened the tank and plastic covers to get access to the ignition assembly. i discovered that the bolts holding the ignition assembly are round so a torx bit would not work. anyone know how to get around this?

472viper

Go to Ace Hardware and get you a torx security bit. I don't remember what size, I think they sell a set for $9.

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2006 M50/C50/109fender/ SE 50 wheels and HD bags
2007 1600 Kawasaki Classic*SOLD*
2008 FLHX Street Glide 105th Anniversary #1387
USAF 1973-1977
SoDak ANG 1977-2010

Run my fingers across the bars of his cage and make the little monkey dance

Two Red Ryders

Seems like a lot of work to lube the ignition switch. If I had a problem with the ignition I would first spray the switch with Corrosion Block and operate the switch a few times Corrosion Block is available at West Marine and on line. I have been using corrosion block for years it fixes lots of electrical problems with switches and connections etc. It both lubes and cleans electrical contacts and switches.

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The United States of America, founded on the principle that "all men are created equal; with unalienable rights; that among these are life, liberty, and the pursuit of happiness Red & Black C50

Two Red Ryders

For those running a lot of extra lights etc one of the best ways to prevent trouble with your ignition switch from over heating is to run the extra light load via a headlight relay drawing directly from the battery. Not only will the relay protect your ignition switch but it often will make your auxiliary lights or more powerful Headlight brighter.

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The United States of America, founded on the principle that "all men are created equal; with unalienable rights; that among these are life, liberty, and the pursuit of happiness Red & Black C50