Ignition fix

[Queensland Ken]

Thanks Brodie,

The harness is a work of art, no problems.

A mate of mine on the Aussie Forum is now going through the process of trying to find out what is wrong with his spyders / wiring.

It looks like a typical S6 failure but his starter solenoid stuck in full time.

Cheers

Ken

 

[Fred W]

...however since Yamaha came out with their recall switch this has become a "non issue" for 2nd Gen. owners.

Well, it has been quite a while now since Yamaha deployed their ignition switch recall. I, for one, was very skeptical that their fix was going to be adequate for all bikes, especially those where the owner had added any accessories that are run off of switched power. Having the key switched contacts operate a relay for handling the higher load of the entire bike (almost), as the "Brodie Relay" does, appeared to me like it was still a great idea.

But it does seem that the data (lack of any post recall failures) speaks for itself. If anyone has had an ignition switch meltdown (not just crusty contacts failure) on an "updated" Yamaha switch installed, please be sure to let the forum know about it.

 

[CAJW]

oldgun

Thank you for the kind words, however since Yamaha came out with their recall switch this has become a "non issue" for 2nd Gen. owners. If you are a 1st Gen. owner that desires to update the ignition switch, I have given the information at the beginning of this thread to enable to build your own. I sold my last copy back in September and will not be making any more.

Take care.

Brodie

One more set of Kudos to Mr. Brodie. I purchased one of his switch harnesses awhile back, opened it up, ate the Tootsie Rolls (don't want them to go stale!) and put it on the shelf. This past weekend, while installing my Autocom and doing a TBS, I finally got around to installing the harness. Aside from the fact that I have so many looms and other crap running through the steering head area, I found the connector and made the install, which was a piece of cake! Thanks again for your persistence and craftsmanship which I'm confident will help keep my Gen I purring for years to come.

 

[beachy]

oldgun

Thank you for the kind words, however since Yamaha came out with their recall switch this has become a "non issue" for 2nd Gen. owners. If you are a 1st Gen. owner that desires to update the ignition switch, I have given the information at the beginning of this thread to enable to build your own. I sold my last copy back in September and will not be making any more.

Take care.

Brodie

thanks Brodie for your easy to follow drawing. After 2 ignition switch meltdowns it was time to tackle the real problem your post and drawing was just what the Dr. ordered Thank You

 

[Hudson]

Brodie, are you still not making the ignition switch fix? Pretty sure my switch just crapped out, and it was originally replaced as part of the recall.

 

[escapefjrtist]

Brodie, are you still not making the ignition switch fix? Pretty sure my switch just crapped out, and it was originally replaced as part of the recall.

Better send him a PM Hudson...this thread is an oldie! Good luck with the repair(s) and let us know if you need a hand with anything.

--G

 

[Hudson]

will do. AuburnFJR has a spare ignition I can test out, but pretty sure that it the culprit.

 

[Diavalos]

I'm pretty sure I have Brodie's harness that I haven't even opened since I sold my 08. Let me know if I can help.

 

[Brodie]

Hudson

I haven't made one of these things for several years now, and I don't think I have all the components on hand. Your best bet would be to become very good friends with Diavalos and take him up on his offer. If it is an official yellow tagged recall ignition switch, you need to get it to your friendly Yamaha service department and give them the opportunity to make good on it.

Bare in mind that my Ignition Relay Harness requires a properly functioning ignition switch - it will not fix a faulty one. All it does is redirect the high amperage switching into a 70 amp automotive relay where it belongs. The ignition switch still performs it's basic function to trigger the relay.

Please keep us up to date.

Brodie

 

[Niehart]

Brodie, are you still not making the ignition switch fix? Pretty sure my switch just crapped out, and it was originally replaced as part of the recall.

And what kind of battery did you install in the FJR my friend?

 

[Mount Rainier]

Brodie, are you still not making the ignition switch fix? Pretty sure my switch just crapped out, and it was originally replaced as part of the recall.

I had the ignition switch recall done at the time it was first available, many thousands of miles ago. No issues at all until a few months ago when the switch, on occasion, would not make contact without a little tweaking of the key. Extra little movement/pressure back and forth of the key was sometimes needed. Once contact was established and the gages etc. cycled, all was good. With the motor running, contact was maintained even with some additional fiddling with the key. I wanted to make sure there weren’t any issues with loosing power while underway.

Then, one morning while preparing to leave home, the ignition switch was completely nonfunctional. (151,430 miles) No mater how many times I tried it, no contact was achieved. Nothing!!! The key functioned fine. The switch was dead. Thank you for the timing on that one for sure......

I ordered a replacement from boats.net and set about removing the brace and switch in preparation for replacement. On a hunch, I purchased some (safe for plastic) contact cleaned from the auto parts store and flushed both the tumblers, and the switch, using the two opens on the bottom of the switch housing for access. I did this a couple of times. After waiting for everything to dry out I reconnected the switch and tried it with instant success. Put the bike back together and have had zero issues over the past 2,500 plus miles. I put a little lube back on the tumblers and it performs as new after many uses.

Because the switch was on backorder, I was able to cancel the order.

Passing this along in case it might help with your issue.

Keep going!

 

[Hudson]

Thanks MR/Brodie/Diavalos. I'll take Diavolos up on this offer to buy the switch, and MR, will again try to flush out the ignition but this time more thoroughly. My experience mirrors yours exactly, and it sure beats the $150 or so for a new switch, plus the hassle factor of rekeying.

Appreciate everyone's input.

Wonder if this is remedied more specifically on the Gen III, as the failure sure seems to be in placing all that current across a less than robust contact.

 

[cactuskid]

I purchased a 2007 FJR used and the key is strange in that the teeth are not the same on each side of the key.
Could this be because the ignition switch was replaced ?
Is there a good way to tell if the ignition switch is original or not ?

 

[RossKean]

I purchased a 2007 FJR used and the key is strange in that the teeth are not the same on each side of the key.
Could this be because the ignition switch was replaced ?
Is there a good way to tell if the ignition switch is original or not ?

Entirely possible that the switch was replaced under recall and that the key is used one way for the ignition and the other way for the bags, gas cap and seat release. (Only one side of the key is used) The ignition CAN be replaced without changing the lock cylinder and/or the other the other locks can be re-keyed so they are all the same.
I think??? the replaced ignition harness has a yellow tape around the wire but to tell for sure that the recall was performed, you can contact Yamaha with your VIN and they will be able to tell you.

https://www.fjrforum.com/threads/fjrf003-1-ignition-switch.113791/

 

[rbentnail]

IIRC there was a dot placed after the VIN on the frame when the recall was done. But that was a long time ago.

 

[RossKean]

IIRC there was a dot placed after the VIN on the frame when the recall was done. But that was a long time ago.

I know the dealers were SUPPOSED to mark with a dot (or punch) but not all did. (Same with the spider recall.) I would still look for the yellow tape on the wire harness (assuming it wasn't removed) and check the VIN with Yamaha.

In any case, it seems likely that the switch (and lock cylinder) were replaced at some point - either for the recall or to replace a failed switch before the recall came out. If the recall was not performed, you should get it done. It is very easy to re-key the saddle bag locks. Not so sure about the seat lock or gas cap (I haven't tried one of those).

 

[rbentnail]

Why go thru all that hassle? With the recall, the ignition switch was re-keyed to match everything else.

 

[RossKean]

Why go thru all that hassle? With the recall, the ignition switch was re-keyed to match everything else.

Should have been re-keyed but I seem to remember a number of people complaining that they had to carry a separate ignition key or get a key cut matching the ignition on one side and all the other stuff on the other. Perhaps some dealers either didn't bother or didn't know how. For that matter, I would think they could swap the old lock cylinder into the new switch. Not sure because I have never examined how they are put together.

 

[fastpappy]

I'd be one of those complainers. The stealer handed me the new ignition key after the recall work was done. Didn't bother to discuss it or inform me ahead of time or give me any option. This along with the other ways they screwed me. Truly a shame, a formerly good dealer who I would recommend with good techs ruined by a new greedy Service Manager.

 

[cactuskid]

A big "Thank You" to all who responded to my questions !!

I will check the VIN tag for the dot and look for the wiring harness tag.
Then I will check the VIN # with Yamaha to see what I can find out there as well.

 

[cactuskid]

I checked the VIN tag today and did not find a dot or punch mark.
I ran a VIN # check with Yamaha and it shows 5 recalls on my FJR with 4 having been completed to date.
The outstanding recall is Bulletin # M2011-003R with a Title of Wire Harness Assy.
There is a completed recall with Bulletin # M2009-002R with a Title of Main Switch.

Another observation that I forgot to mention is the gas cap is not locking and looks to be an after market item.
I am thinking that this might have something to do with the strange key issue and have attached a photo of the gas cap.

My all means please share your comments / experience with me on this issue.