TILAM, since you do have the 06, and all the issues with the switches, if you haven't already, you might want to do what I did yesterday with the harness Brodie is making up for us by installing it into the plug you speak. It takes the main strain of wear off the the ignition switch and puts it on the relay in the harness he is making and selling. Thus making the ignition switch last and help eleminate the failures we've been seeing especially in the 06 models. PM. <><
Ignition Fix
You might want to check out this list of owners who have reported failures on the switch. I noticed off the first couple of pages two were from Canada. Its a good place to start.TILAM, since you do have the 06, and all the issues with the switches, if you haven't already, you might want to do what I did yesterday with the harness Brodie is making up for us by installing it into the plug you speak. It takes the main strain of wear off the the ignition switch and puts it on the relay in the harness he is making and selling. Thus making the ignition switch last and help eleminate the failures we've been seeing especially in the 06 models. PM. <><
Ignition Fix
I have been following this ignition switch thread since it first came out. I have been experiencing intermittent problems with it since June. Mine isn't the broken wire syndrom that is the most common but the "dirty contact" problem I think. Anyway removal and dis-assembly should tell.
As a side note, we in Canada have the Eurpean type switch with the "security chip". The switch is likely of a different manufacture and I don't know if they have ever been identified as having the broken wire type problem. Can anyone confirm this?Thanks for the information regarding the plug.
Yes, do disassemble. Carefully inspect the white plastic carrier that has the spring loaded contacts for *any* thermal distortion. You can see the distorted part of the carrier in this picture.
Tillam
Sounds like you have the fuel tank propped up and are reaching under and around things. The fuel tank is an easy removable item on out bikes. Undo two wire connectors (with tabs easy to locate), quick disconnect the fuel line, disconnect two rubber hoses on the outer left rear of the tank and it will lift right off. This way it's easy to reach the whole top end of the engine bay.
The symptoms you have described sound exactly like what my switch showed before my "fix". The good news is ( if your bike is a lower 48 states model without a security chip) once you "easy out" the tamper proof screws you can index the plastic carrier 180 degrees and will have in effect a brand new used switch. That is what I did with my unit.
I'm happy to be a member here to all these friends to help me out. I'll let you know what the findings are when I get deeper into it.Tillam
Sorry I didn't respond earlier, I hope you got past this silly thing.
The wire harness connector does indeed have a catch to it, it is a small ramped pin which fits into a narrow slot on the mating part.
To get it apart you can use a small jewlers screw driver to slightly spread the thin wall and just slide the assembly apart.
Sounds like you have the fuel tank propped up and are reaching under and around things. The fuel tank is an easy removable item on out bikes. Undo two wire connectors (with tabs easy to locate), quick disconnect the fuel line, disconnect two rubber hoses on the outer left rear of the tank and it will lift right off. This way it's easy to reach the whole top end of the engine bay.
The symptoms you have described sound exactly like what my switch showed before my "fix". The good news is ( if your bike is a lower 48 states model without a security chip) once you "easy out" the tamper proof screws you can index the plastic carrier 180 degrees and will have in effect a brand new used switch. That is what I did with my unit.
When you complete this repair and get the switch back in your bike, you need to add a relay to the circuit. That way it will never burn out again.
Hope this helps
Brodie
It's a term I've used for years, might be an English reference. And yes it is a good thing, usually a very good thing.
