gen 1 ignition switch

[drjfjr]

I am in macon Ga after riding 518 miles today, Last gas stop all seemed well and as i was trying to get on to the access rode and let off the throttle it acted like it lost power unless i held the throttle open a little. On the expressway and all was good. took an off ramp to find a hotel and as soon as it went to idle dead. I mean totally dead. I checked the battery and had 13.2 volts. I knew I had to get an electrical schematic so I pushed the bike to the nearest hotel which was fortunately down hill and broke out the lap top with the service manual. raised the tank and started checking the ignition switch. No continuity. The gas station did not have any electrical switches so I inquired where to find some. The only place they knew of was a walmart 2 blocks away. They did not have any rocker switches but they did have a 4 wire trailer cable extender. Well with some tape and butt splices I turned the 4 wire sae connector into a switch. i take one end that is jumped and plug it into the other end to complete the electrical connection. the trip can go on. I will be ordering a new ignition switch and hopefully it will be at home when I get there.

The bike is a 2004 with 50k when the switch died.

 

[SkooterG]

Weird. Gen I switches usually don't die so suddenly in that manner while actually running. Glad you were able to get it running again.

 

[huron52]

I am wondering if it wasn't a TPS problem and not a switch? Has it ever been replaced? The TPS that is.

 

[drjfjr]

The TPS was done during the recall and that would not kill gauges and all else. I thought it was the battery since it ran until I went to idle. I guess enough current arced across the contacts until idle. I was expecting the ECM or main fuse which is why it took me longer to diagnose the problem. Raising the tank and checking the switch was the last thing I considered and it proved to be the issue. The ignition switch is bypassed and it starts and runs fine again.

 

[drjfjr]

Weird. Gen I switches usually don't die so suddenly in that manner while actually running. Glad you were able to get it running again.

yes it was wierd, that is why i looked every where else first.

 

[FJRay]

That's just about how mine died on the way to WFO in Park city. I was able to get enough WD40 into the bottom of the switch to get it to the rally and going for a bit but the last time I got it going I never shut it off until I was home. I took the switch apart and cleaned all the contacts. At the same time I made my own relay system and it's still on the same switch. I still carry jumpers in case the relay dies.

 

[UHOH]

The bike is a 2004 with 50k when the switch died.

my 2004 became intermittent when turning on ignition at 58,000.

needing several on / off cycling. never cut off when running though.

new switch...

68000 now, all's OK.

 

[drjfjr]

Wow second day on trip and datel started dropping voltage like a rock in a river. I pulled over and started checking things 2 hours later i found a bad toasted connection on the rectifier. took apart the oem connector and hooked up the stator direct without the factory connector and all was good then. I we will see if all is well as i progress on the trip. The datel readings since this fix have been 14.4 on avarege since the fix. I will do a trip report and result of fixes on this trip as we go just too late tonight to start.

 

[SkooterG]

Man, you have had some bad juju. Hope things get better and no more issues!

At least you had a Datel and were able to see the problem developing.

 

[FJRPierre]

Mine suddenly stopped working at a gas stop in Tenn a couple of years back at 90K km. Dealer did a bypass with an ATV switch and still going strong, (if I can just remember to use the ATV key and not the FJR key lol.) Some day I take the ignition apart and resolder, and maybe wash my bike at the same time...maybe, maybe not.

 

[drjfjr]

Day I met up with friends

As stated I had some ignition switch issues so here is how I was able to continue the trip:

Day 2 started well

after a few hours I had lost battery charging and found this

The rest of the story I will put in a trip report later this week. I have ordered a new ignition switch and 70 amp relay to get the high current out of the switch. 6 hours of the first two days of the trip were on these two issues. Glad I had the Datel mounted. I would have been stuck on the exspressway.\

 

[RadioHowie]

dr,

time to dump that POS Gen I and think about upgrading to a Gen II with it's new and improved electrical system!

:devil:

 

[drjfjr]

so when are you upgrading? :lol:

 

[steve'o']

HaHa, I bet Howie would take that so called "POS" off your hands real quick. Maybe he needs some parts.

 

[HotRodZilla]

HaHa, I bet Howie would take that so called "POS" off your hands real quick. Maybe he needs some parts.

Of course he needs parts. That antique bike of his is falling apart. It already has a replacement motor...Something else is just waiting to break on such a reliable GenI machine.

 

[beemerdons]

HaHa, I bet Howie would take that so called "POS" off your hands real quick. Maybe he needs some parts.

Of course he needs parts. That antique bike of his is falling apart. It already has a replacement motor...Something else is just waiting to break on such a reliable GenI machine.

 

[HotRodZilla]

HaHa, I bet Howie would take that so called "POS" off your hands real quick. Maybe he needs some parts.

Of course he needs parts. That antique bike of his is falling apart. It already has a replacement motor...Something else is just waiting to break on such a reliable GenI machine.

Whatever loser....If you could lick your own balls, you'd never leave the house!

 

[RadioHowie]

so when are you upgrading? :lol:

 

[BackintheSaddle]

Wait....you broke while riding with a couple of Harleys????? Irony is a cruel mistress.....