Gen 1 ignition switch failure

[mattster31]

Last night I went out to start her up and............................nothing.......dead. I thought battery? but my HIDs I just wired up direct still work, my alarm still functions....WTF??

Take off the panels to check main fuse......it's good.

Check other fuses....good there.

Check battery terminals.....positive side a tiny bit loose, but not sloppy.... tighten..... still dead (battery 12.6)

Then I repeatedly cycle the ignition switch (forcing a small amount of pressure past on), and as I do this the gauges begin to flicker....WTF? Have I got a switch failure?? I thought that was only on Gen II models?

Anyways, it starts up, and I ride home. I tried to see if I could replicate the failure but the switch seemed fine. I thought since it was parked in the rain yesterday, that perhaps a bit a H2O affected things, so I spray in a bit of WD40.

Go out today, starts up fine. I think I'll be removing the switch to inspect this week. I'll post photos of what I find.

Here we go.......

Pic 1 - this is what you see when you remove it. Damn things have to be drilled out :-(

Pic 2 - this is what you see after you drill out the bolts. Easy enough to twist out the studs with some vice-grips.

Pic 3 - this is the unit disassembled. the contacts were just cruddy and required a good cleaning.....no loose wires. Just re-assembled with new bolts and it's done!!

 

[jhedges]

Something similar happened to me last week. I washed the bike and evidently got some water in or near the ignition switch. I rode it to work the next day, and after work I went out to go home, and the switch would not turn. It was like it was in a locked position. I eventually got it turned and started. When I got home I would some wd-40 in and around the switch. Hadn't had a problem since. And I'll also take some precautions when I wash the bike again.

 

[beemerdons]

Sorry mattster31, that has never happened to Miss Lucy Liu, my 2003 FJR. But then again, we don't park our bikes in the rain much here in Phoenix; only about eight to ten days in a good year.

Looking forward to your follow up report; since Lucy, Son Seth and I will be in Mont-Tremblant, Quebec next month: CFR. Rather do preventive maintenance before Ms. Liu actually sees any rain.

 

[Bustanut joker]

Don't sweat the rain burro nuts.. It's me relieving myself ya have to worry aboot.

Elenor's been rained on more than she's been dry and I haven't had a problem ..... Yet.

I spray WD in the switch three or four times a season though.

:jester:

 

[Bungie]

The switch on my 04 occasionally was hard to turn so I shoved a bunch of rags underneath it and hosed it out good with some contact cleaner. Lots of **** came out of the bottom. So I did it a few more times then followed it up with some WD40. Haven't had any problems with it since.

 

[FJRay]

BTDT Mine did it on the way to WFO in Park City. Left me in the middle of Wyoming. finally got it going just like you describe. Kept soaking it with WD40 and made it through the rally but it gave up for good on the way home.

I took the whole thing apart and found junk inside the switch and ugly contacts. After a good cleaning and building my own relay harness ( I wasn't smart enough to make them for others like Mr. Brodie) its been fine. I still cary premade jumpers in case it dies again.

 

[beemerdons]

Don't sweat the rain burro nuts.. It's me relieving myself ya have to worry aboot.
Elenor's been rained on more than she's been dry and I haven't had a problem ..... Yet.

I spray WD in the switch three or four times a season though.

:jester:

Well, this is very interesting! When did you switch to WD40? I remember a technical article you wrote for our FJR Forum back in 2007, where you advised jacking off regularly on the ignition switch.

 

[SkooterG]

Dirty switch. Same thing has happened to me three times in 225k. Still on the original switch. That's why in the past I have been so adamant that peeps cycle the switch repeatedly before assuming their switch is fried and replacing it. There is a post by Barabus where he disassembled his 'broken' ignition switch only to find the only problem with it was dirt. It has good piccies.

Yes, there have been a few examples of Gen I's frying their switch, but they are fortunately extremely few and far between.

 

[Bustanut joker]

Don't sweat the rain burro nuts.. It's me relieving myself ya have to worry aboot.
Elenor's been rained on more than she's been dry and I haven't had a problem ..... Yet.

I spray WD in the switch three or four times a season though.

:jester:

Well, this is very interesting! When did you switch to WD40? I remember a technical article you wrote for our FJR Forum back in 2007, where you advised jacking off regularly on the ignition switch.

I'm going to have to **** in yer tank ain't I....

:jester:

 

[Canadian FJR]

That's the way mine started. About a year later it died while in motion, that was fun. I now always carry a jumper kit, simply connect the brown and red wire for a temp fix. A complete description on how to do the repair is shown below.

https://www.fjrforum.com/forum//index.php?showtopic=103354

Good luck,

Canadian FJR

 

[charismaticmegafauna]

Yes, there have been a few examples of Gen I's frying their switch, but they are fortunately extremely few and far between.

Not only Gen Is, but motorcycles in general -- spotty failures all over for decades. Ignition switches are generally mounted in a handy, but exposed, place.

Periodic maintenance (as stated here) with, something-like, contact cleaner and spray silicone (read the label -- no acetone, etc.) may not be a bad idea. Also, careful operation of the switch as well as some protection from the elements when it seems really necessary may be good ideas? Too, a minimum of 'junk' on the key ring probably can't hurt.

Maybe the old mechanical switch will give way to modernity with something-like Kawi's 'K-Pass' keyless system?

Check battery terminals.....positive side a tiny bit loose, but not sloppy.... tighten..... still dead (battery 12.6)

Terminals = clean, tight, and a little lube (like vaseline)...

12.6 V. = a little low (for a modern FJR battery). 12.8 V. (75% charge) should, maybe/ideally, be the minimum -- up around 13 V. is good.

 

[beemerdons]

Don't sweat the rain burro nuts.. It's me relieving myself ya have to worry aboot.
Elenor's been rained on more than she's been dry and I haven't had a problem ..... Yet.

I spray WD in the switch three or four times a season though.

:jester:

Well, this is very interesting! When did you switch to WD40? I remember a technical article you wrote for our FJR Forum back in 2007, where you advised jacking off regularly on the ignition switch.

I'm going to have to **** in yer tank ain't I....

:jester:

Bust, you are the sole reason that our FJR's come with locking gas caps!

 

[flying junior]

My Gen 1 switch just died in the middle of the commute on a bay area freeway when I was splitting lanes. I managed to get over on the median before I ran out of momentum. Finally got home and did a post mortem the next day. One of the wires had come unsoldered from its contact. Those wires are held in place only by the solder! There is no mechanical connection whatever.

The switch carries a lot of amps. I put one of brodie's relays in the circuit to handle the load. The new switch works fine. I got a locksmith to rekey it to my old key.

 

[mattster31]

BUMP for repair photo's!!!

 

[Zorlac]

I just shoot some Pro Gold into the weep hole with the switch still on the bike, no troubles since.

 

[SkooterG]

the contacts were just cruddy and required a good cleaning.....no loose wires.

Told ya so.

I've never done one single thing to clean mine. Just cycle it till it works again.

 

[FJRPierre]

I have a Canadian 2003 (90,000km). I stopped for gas in Asheville NC, paid up and then wtf no power, no lights, needles, nothing, nada. tore the plastic off and checked all fuses with no obvious problems. could get a very intermittant surge ( needles go haywire) with ignition "off" and rubbing black wire connector to battery post. Towed to a wonderful dealer in ashville MR Motorcycles who tells me he'll check the battery but he'll bet that its a busted ignition. He tries to see if there is a recall on my03 but yamaha usa wont recognize a canadian vin so no help officially. and he has none in stock anyway. but the wonderful tech (seriously) says he has jury rigged such ignition by inserting an ATV ignition in the circuit. which he did and voila i have power. I tie tag the new switch beside the old one, get 2 ATV keys, pay the man and i'm on my way (3 hours later after i reinstall all the tupperware.

Back home talk to Yama Canada Customer service, says there is no ignition recall on 03s, it's been 7 years and these things fail, and I should get the switch fixed properly (with a new yammy switch identical to the one that failed). I advise that I'll be reporting the safety issue to Transport Canada.

(and i just found this thread so will be looking at the problem more closely)

 

[mattster31]

I was bummed when it happened that's for sure, but after all that work tearing it apart only to find it was a bit dirty was a little dissapointing. NO loose wires of any kind.

 

[Canadian FJR]

FJRPierre - PM sent.

Canadian FJR