Ignition Switch Trouble?

[zoom45]

My 02' 1500 carbed Nomad has an intermittent problem and I believe it's in the ignition switch. Sometimes it may be hard to crank and will almost run the battery down before I can get it started. Sometimes I can be riding on a smooth interstate at speed and it will just cut off and then it will come back on itself or I can wiggle the key and it will backfire then start running smooth again. It may not do it for 1000 miles then it will all of a sudden do it again. I was in traffic the other morning and it all of a sudden died. I pulled over turned the key off then back on and it worked fine the rest of the day. I've ruled out the main power switch and kickstand switch. The wife couldn't believe I knew it had a problem and we still went on a trip. LOL. I checked the OEM ignition key set and it's about $300. I may have to take it apart to see what's wrong or just replace it. It could be dangerous on the interstate if your in the left lane with heavy traffic and it quits. Has anyone had this trouble on a 1500?
Zoom45

[cactusjack]

Not sure if it can be taken apart, but it could just be the contacts need cleaning. Do you have any devices like driving lights powered through the bike wiring? High-draw devices like that can fry the switch contacts, which is why I tell people to wire them on a dedicated circuit to the battery.

[dantama]

My 99 did similar things, I got another ignition switch from a VROC member, and wanting to keep my same key, I put pieces from both together. It was about 7 years ago, don't remember much about the process except not to lose the small bb sized bearing that is part of it.

End result was the problem was solved. Perhaps go on the part for sale forum and ask around for an extra ignition switch.

[lomax]

...Check your battery cable connections. Make sure they are clean and tight. A poor connection at the battery can cause some strange things to happen. :)

[ringadingh]

I have a similar problem with my switch, but only on starting. It doesn't turn the fuel pump on always, I have to turn it on and off a couple times for it to make contact sometimes. Ive taken mine apart twice and its a contact that sticks sometimes, cleaning helps but is only temporary. Watch out for a couple small springs in there.The OEM switch is only about $83.00 when I priced one in the spring. When I do replace mine it will most likely be with a Harley style switch which sell for about $25.00 on Ebay. Then I can relocate it to a more convenient location.

[macmac]

Are other keys on any ring? While I don't know about kawii having a problem with other keys causing weight and so wear, I know of certain cars that do....

'IF' you can wiggle the key while the engine is running and the engine screws up you can bank on the lock is going bad.... I don't know if this is a sealed unit or not.

[chuckster131]

Zoom,
You can take the back off and clean the contacts. Be careful as there is some very small parts in there. (Trust me) I know!
If you still have trouble you can go with a handlebar mounted switch I make like this one, for half the price of the OEM ignition key set from Ma Kaw

[ringadingh]

Originally Posted by macmac

Are other keys on any ring? While I don't know about kawii having a problem with other keys causing weight and so wear, I know of certain cars that do....

'IF' you can wiggle the key while the engine is running and the engine screws up you can bank on the lock is going bad.... I don't know if this is a sealed unit or not.

I only have two other keys on the ring and its fine once it starts. Ive had it apart it and you can see that the contacts are worn and don't make a good connection all the time. Im sure once I replace it everything will be fine again.

[Cajunrider]

Originally Posted by chuckster131

Zoom,
You can take the back off and clean the contacts. Be careful as there is some very small parts in there. (Trust me) I know!
If you still have trouble you can go with a handlebar mounted switch I make like this one, for half the price of the stock switch from Ma Kaw

That's a nice looking switch Joe.

[cactusjack]

Originally Posted by Cajunrider

That's a nice looking switch Joe.

That's what I was thinking - very nice. Where does the key go? I guess there's a cap that covers the keyhole.

[Jared]

Originally Posted by macmac

Are other keys on any ring? While I don't know about kawii having a problem with other keys causing weight and so wear, I know of certain cars that do....

'IF' you can wiggle the key while the engine is running and the engine screws up you can bank on the lock is going bad.... I don't know if this is a sealed unit or not.

Can't you pull the key out of the ignition on the 1500? I never ride with my key still in the ignition. I actually hardly use the key at all. With the key out, if you turn the ignition between the off and on position, it turns everything off and a key isn't needed to turn it back on.

[ringadingh]

No Utah; the key has to be in on the 1500's all the time. Considering the bike is going on eight years old that not to big a deal. Its seen a lot of use the last few seasons and hopefully will see a lot more.

[macmac]

1500 is different in location and has no keyless use as stock. I didn't know if the 1500 lock could be taken apart or not, but if it can it is probably typical of other locks.

Some copper tabs and little springs... A clean white pillow case comes to mind and not working on a sand gravel floor area...

(With that said we got ce-ment in the barn! Now I just gotta get all the tools back in there.)