There have been numerous reports of the KIPASS system malfunctioning over the last year. Almost all of these failures can be traced back to a switch that sticks inside the steering lock mechanism. I contacted Kawasaki Tech support and was informed that there have not been any changes to this switch, and no plans are in the work for a change that they are aware of. There also is no plan for a recall of any sort, and new 2009 bikes have the same switch. Basically what happens is when you press in on the key knob, it activates a switch that tells the steering lock and KIPASS ECU to perform the authentication of the FOB. But when the switch sticks in the down position, the system shuts off after a few seconds and you can't get it to re-authenticate. This means you can't turn the key because the steering lock won't release the solenoid that prevents it from turning until the authentication is performed. So basically, you are hosed. You can't turn the key and you can't start the bike. I took mine apart this evening to photograph it and take a look at the problem myself. The first thing you have to do is remove the handlebars and top triple clamp or "top bridge" assy and unplug the electrical connector from the wire harness so you can remove the steering lock unit and triple clamp from the bike. Then you will see that the steering lock is held on with security screws in the bottom of the triple clamp that have been filled in. The only way to get them off is to drill them out. Once you have the steering lock free you can see the switch. It appears what is happening is dirt and contaminates are getting into the switch and causing it to stick. The well around the Oven Key probably isn't helping any either, since it acts like a trough to collect water and wash it down into the switch. I washed the switch out real will with silicone spray and then packed it with a liberal dose of dielectric grease. However, I would caution anyone AGAINST spraying ANY LUBRICANT into the lock cylinder itself. This can do more harm than good, and it is not the lock cylinder that is sticking, it's the switch below it at the 9 oclock position. If your switch sticks you may be able to get it free itself by tapping at the 9 oclock position just below the key. This may be enough to jar it loose and help you get home. You can also temporarly fix it by disconnecting the large multi-pin electrical connector for the steering lock that is in the black rubber boot under the left side black panel (where the left glove box would be if the bike had one). By breifly disconnecting and then reconnecting this connector, it will break contact of the circuit, and you should then be able to turn the key if you do it within a few seconds of reconnecting it. You can find the connector by following the wires from the steering lock back to the main harnes on the left side. I will keep in contact with Kawasaki about this, but I'm not holding my breath that they will take action. Maybe after enough complaints surface at dealerships they will take action. I put a complete photo gallery of the switch on my photo site here: http://www.pbase.com/fredharmon/kipass Here are a couple photos so you can see the switch. I won't put them all on this thread cause there are too many.
