REBUILDING AN IGNITION SWITCH

[Mike-C]

Good Day Gents;
The ignition switch on my 1200 is slowing signs of failure, when I move the bars the engine cuts out at low speeds. I'll check the big plug tomorrow. Has anybody ever rebuilt one? I think they are NLA from Honda.
Mike Coleman
'84 Wing-Lite (ex-Aspencade)
'84 (un-Terstate)
'84 Standard (as yet un-named)
'96 Kawasaki Vulcan 1500 (The Vulcanator)

[Lucien Harpress]

Not sure about 1200 availability, but I had this problem on my 1000 and all it took was a new set of plastic guts/contacts on the bottom of the switch. The old one snapped off and the new one snapped on, with a plug on the one side to connect it to the wiring harness. For all the fanciness that is the key and tumblers, all that does is spin the top of the contacts. I believe Emgo made the replacement parts, which have a so-so reputation, but it worked fine for me.

Honestly the hardest part is probably getting the switch out. After that it's a piece of cake.

[Mike-C]

Hello Lucien;
I was just looking at my local Honda dealer's parts site and they show the white plastic 'thingy' with its ball bearing contacts, I call tomorrow to check availability and price.
Thanks;
Mike Coleman
'84 Wing-Lite (ex-Aspencade)
'84 (un-Terstate)
'84 Standard (as yet un-named)
'96 Kawasaki Vulcan 1500 (The Vulcanator)
Mike Coleman

[ericheath]

I pulled one for my 1000 apart once. The copper alloy contacts are riveted to the base. Once they become loose, you get intermittent contact. Several million brain cells back, but I think I just tapped them snug again with a punch and hammer and it worked until I found a replacement from Partsnmore. The contacts are in plastic so you can’t really hit it very hard as best as I recall.

Not an easy place to view but check the connector for wear or a misplaced wire/ cable that could be pulling in it as you turn the bars.

[Mike-C]

Gents;
I took my switch apart, cleaned all the contacts with WD40 and Scotchbrite and reassembled it with dielectric grease, problem solved.
Thanks to all;
Mike Coleman
'84 Wing-Lite (ex-Aspencade)
'84 (un-Terstate)
'84 Standard (as yet un-named)
'96 Kawasaki Vulcan 1500 (The Vulcanator)
Mike Coleman