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Author Topic: ignition switch?  (Read 1258 times)
csj
Member
*****
Posts: 992


I used to be a wolfboy, but I'm alright NOOOOOWWWW

Peterborough Ontario Canada


« on: July 02, 2016, 05:58:23 AM »

Noticed this morning that the headlight, running lights, tachometer, neutral and high beam
indicators are all out. The brake lights and horn work.

After hunting through the schematic in  my shop manual, it seems that the voltage feed
for these items comes from the Ignition Switch.

I'm trying to take the switch apart, but it requires a special tiny torx driver. Though I have
most tools you could ask for, I don't have that. (going to buy it today)

So, do you think I'm on the right track?

Oh, thought about a broken ground, but the brake light shares that same ground, and brake
light works. So it is likely not a ground broken.
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A guy called me a Ba$tard, I said in my case it's an accident
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csj
Member
*****
Posts: 992


I used to be a wolfboy, but I'm alright NOOOOOWWWW

Peterborough Ontario Canada


« Reply #1 on: July 02, 2016, 06:19:11 AM »

The fuses are all good, and the bike runs well.
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A guy called me a Ba$tard, I said in my case it's an accident
of birth, in your case you're a self made man.
Gryphon Rider
Member
*****
Posts: 5227


2000 Tourer

Calgary, Alberta


« Reply #2 on: July 02, 2016, 08:02:35 AM »

I've never had my switch apart, so can't offer you advice there, but use a test light to confirm you have power for the other circuits coming out of the switch, but no power for the circuit in question. That way you can eliminate wiring/connector issues as the possible cause.
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csj
Member
*****
Posts: 992


I used to be a wolfboy, but I'm alright NOOOOOWWWW

Peterborough Ontario Canada


« Reply #3 on: July 02, 2016, 12:24:31 PM »

Finally got the switch apart. The 'Torx' driver is a security type, with a hollow center.
I couldn't see the center post inside the switch' screws.

Used the trouble light to see that one of the Red wires does not have any juice
when the key is on.

So now, I'm at the outside of the switch where the wires enter it. I'm now trying
to get further into the switch, to find where the problem is.
Logged

A guy called me a Ba$tard, I said in my case it's an accident
of birth, in your case you're a self made man.
Gryphon Rider
Member
*****
Posts: 5227


2000 Tourer

Calgary, Alberta


« Reply #4 on: July 02, 2016, 01:00:17 PM »

Both red wires (solid red, not striped with white or black) at the switch should have power all the time, even when the switch is off.  The red wire that comes from the 30A fuse at the starter relay goes to the ignition switch.  Somewhere in the wiring harness (probably quite close to the ignition switch), a second red wire is spliced to the first one, and then the two of them go to the ignition switch to power everything else.  If one red wire has power and the other doesn't, there is a break in the unpowered wire somewhere, which is the cause of your problem.

Look at the appropriate S1 diagram here, either the Std/Tourer one or the Interstate one depending on what you have, to see what I mean.
« Last Edit: July 02, 2016, 01:05:32 PM by Gryphon Rider » Logged
csj
Member
*****
Posts: 992


I used to be a wolfboy, but I'm alright NOOOOOWWWW

Peterborough Ontario Canada


« Reply #5 on: July 02, 2016, 01:19:33 PM »

Got a 98 Tourer.

Got the entire ignition switch apart. The rotary part that the key
moves has a small board with small (I'll call them 'solder') balls that make contact
with flat contacts on the inner mating part.

Somehow the 'balls' were not touching the contacts. You can't actually, or perhaps
easily get in there and clean anything. I twisted and spun the rotary part a few times.
Was able to get headlights and signals and (I hope) everything else lit up.

I'm thinking to get some 'contact cleaner' and spray it in there. Could be a film of
some kind making contact bad.

I'll be keeping the 'hollow torx' with me in the saddlebag, in case this happens again.

GR, thanks for the help. 
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A guy called me a Ba$tard, I said in my case it's an accident
of birth, in your case you're a self made man.
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