Author Topic: Ignition Switch Removeal  (Read 953 times)

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Offline Pete

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Ignition Switch Removeal
« on: May 12, 2011, 10:46:08 pm »
I need to remove the ignition switch on a 91.
What is the best way to accomplish this ?
Thanks.
Pete

Offline GF-in-CA

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Re: Ignition Switch Removeal
« Reply #1 on: May 13, 2011, 02:50:37 am »
Pete,

The ignition switch is fastened to the top triple clamp with tamper resistant screws, meaning the screws are designed to not be easily removed.  I've only done this once, so others may have a better method, but to start, you will need to remove the top triple clamp.  You can disconnect the switch wiring at a connector down near the frame.  To get the screws out, I ended up using a die grinder to grind off the screw heads to the point where the switch could be pulled off with the screws still in place.  With the switch off, you can use pliers to remove the old screws.  Use some socket head screws of the same size and length as the old screws to reattach the switch.  Reinstall the top clamp, reconnect the wires, and you're ready to go.
Gary F.

1998 ZGX1100
Central Valley California

Offline Pete

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Re: Ignition Switch Removeal
« Reply #2 on: May 13, 2011, 04:12:40 pm »
Gary... thanks for your help.... that's what I thought... but wanted to confirm it with some one that has done it before.
Pete

Offline Rev Ryder

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Re: Ignition Switch Removeal
« Reply #3 on: May 13, 2011, 08:59:15 pm »
I have also gained access by pulling the upper fairing to expose the bottom of the mount and switch (I've done this several times and used a different method each time).  I agree that pulling the upper triple is about as easy as it gets.

A couple of ways I have used to pull the screws once you have access is to:
a. Using a dremel cut-off, grind a slot in them and then use an impact screw driver on em.
b. Set a nut over the round heads and MIG it on.  Then while still fairly hot I just grabbed a wrench and turned them out easily.

IHTH
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 Shafties Can't Wheelie