Replacing Ignition Switch

Spout · Apr 20, 2012

I'm having to jiggle my key a few times before getting any power through. So a new ignition switch will have to go on this weekend.

Any tips or pitfalls to look out for?

I assume the only way to get the security bolts out is by drilling?

Cheers

Steptoe · Apr 20, 2012

Spout said:
I assume the only way to get the security bolts out is by drilling?

Cheers

6mm drill, a quick whizz couple mm deep then whack a torq bit into the bolt and undo.

Saves fecking about drilling the whole thing out.

scottpa · Apr 20, 2012

I had a similar problem with my ignition switch. There is a microswitch (part number 2 in the diagram) at the bottom of the ignition. That is what turns the power on. This is what I had a problem with. You don't actually need to take the ignition out to get to it. It unscrews from the bottom of the ignition.

Try removing it and giving it a clean / squirt of WD40 and see if that fixes the issue.

Otherwise I believe you are correct and you need to drill out the security bolts to remove the entire ignition barrel.

Regards,
Alan

TLSgazza · Apr 20, 2012

As said above. Mine had a problem with the switch screwed to the bottom. I bought a new one and replaced it in about 10 mins. Worked fine. Ever since

Spout · Apr 21, 2012

Cheers guys.

Unfortunately the computer was "down" at Williams today, so even though they had the part in (checked during the week) they didn't know where it was :nenau

So I had to leave empty handed.

Try again next weekend :augie

FERRET · Apr 21, 2012

So much for the computa age :blast

, cant beat paper and pen :thumb2

or even pen and paper

ianm00 · May 8, 2013

I have an 06 R1200GS from new and used everyday (Covered 78064 miles).

Over the last few weeks when I turn the ignition key on occasionally I don't get any power and with trying the key again it has always powered up. I think the micro switch item two in thr previous diagram is going faulty.

Can this be removed without removing anything on the bike ie with the ignition barrel etc in place.

How do the wire plugs come off any catches etc thet have to be depressed or something?

Thanks

Ian

Agrajag · May 8, 2013

Depressing Catches

How do you go about depressing a catch?

"your the worst catch I have ever seen? You couldn't catch a cold."

etc

ianm00 · May 8, 2013

Agrajag said:
How do you go about depressing a catch?

"your the worst catch I have ever seen? You couldn't catch a cold."

etc

Why bother answering? T**T comes to my mind

Some electrical connectors have latches that need to be pressed before the connectors can be separated.

ianm00 · May 9, 2013

Anyone know how to remove this micro-switch?

Do I have to disconnect the harness or can the switch be removed with the ignition all in place on bike?

Sgt Bilco · May 9, 2013

ianm00 said:
Anyone know how to remove this micro-switch?

Do I have to disconnect the harness or can the switch be removed with the ignition all in place on bike?

It unscrews easily with the ignition in place and will only take a few minutes to change :thumb2

Boxerboy55 · May 10, 2013

Steptoe said:
6mm drill, a quick whizz couple mm deep then whack a torq bit into the bolt and undo.

Saves fecking about drilling the whole thing out.

Changed out my EWS a while ago and found removing the security bolts to a real PITA. Drilled the heads off without too much trouble. Actually I lie, big boy showed up and applied most of the muscle. Then the EWS was free but the remaining studs were REALLY tight with some thread seal so I bliistered my hand undoing them with small mole grips. Which I had to go buy specially.
Then the new EWS was fitted in a few minutes with normal screws.

Spout · May 10, 2013

scottpa said:
Try removing it and giving it a clean / squirt of WD40 and see if that fixes the issue.

OP update: New microswitch was purchased, but has remained on the shelf for over a year. I thought I'd wait until I next had the front end of the bike apart.

Problem has been temporarily solved (over a year and 10,000 miles) by a single liberal application of WD40 through the keyhole. :clap

The reopening of this thread has reminded me I need to do the more permenant fix :augie

ianm00 · May 11, 2013

Can I remove just item 2 from the picture?
Do I need to remove item 7?
Do I need to drill out the security screws and remove the EWS unit as well?

Looking on the bike its difficult to see which screws and which parts need to be remove.

Thanks

Ian

Treksec · Jun 20, 2020

If the ignition is intermittent, it's most likely the micro switch in the module beneath the ignition barrel. Easy DIY job, 20 mins. Part number 61318543110, £83 delivered from Motorworks. You will need a T10 bit to remove four screws, two from the shroud and two from beneath the switch module, a work lamp and a pair of small snips to cut the cable ties on the original switch module. Remove the shroud, which can be done from a standing position, then turn the handlebars all the way to one side. Cut the cable tie holding the wiring to the faulty module. From underneath, remove the electrical plug from the faulty switch and the two grub screws holding it in place. Pull the switch away and installation of the new switch is the reverse of the removal. Bingo.

Replacing Ignition Switch

Spout

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Steptoe

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TLSgazza

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