I'm in the middle of installing my painted inner fairing and the Arc mini amp.
I removed the ignition switch, it was a piece of cake.
Went to install it and I can't can't get it back in.
The forks are in the locked position and the cap almost back but it won't go any further. How hard should I have to press on it?
Is there any other trick or do I have to get the ignition alignment tool.

Any help is greatly appreciated.

 

Read this thread it should help.

https://www.hdforums.com/forum/touri...on-switch.html

 

there trickey.take a pen light shine down and align the tumblers **** should slide in.......good luck

 

Take your time and look at the shaft carefully. I had the same problem first time I took mine off. It's a goofy combination when installing the shaft/ignition switch. sorry but hard to explain. When installing make sure you turn it the additional 60 degrees. It make take a few "wiggles" to line the keys up.. MAke sure it's reinstall in the Fork lock position when inserting. You should hear a few clicks when it's installed properly....Only Caution: hope you didn't remove it from the "access" position if you did you'll need an alignment tool.. It's like a puzzle first time.....hope this helps

 

Do you have a manual? It tells you excatly how to re install it. I played around with it with no luck until I read it carefully. I'm not at home but let me see if I remember. When you put in the igintion start at the access and turn it until it drops to below the first tumbler but on top of the second one. Then look below at where it stops. If it moves two spots to the right then the bottom tumbler needs to move two clicks to the right and so on. After that put the unit back in and it should fall into place.

 

One side of the shaft is dovetailed, the other is square. cut down a paint stir stick then slide it in and turn the tumblers until you all of the dovetailed grooves on one side and the squares on the other.

 

Now that's what I call ingenuity... I love it!!!

 

I messed mine up to. I am willing to tear down and reassemble a whole bike but I won't mess with that stupid switch, they say you need patience.

 

Ahhh, that is exactly why I got the ignition alignment tool for Christmas!

 

Hey, just had mine off a couple of hours ago to do the passing lamp "always on" mod. Came out easy but got messed up putting it back together. Did not mess with moving the steering at all and knew the alignment was ok. To fix mine I removed the lock, made sure the key was pressed in and turned to the left, slipped it back down the tube, turned the key slightly to the right, heard the click and all was ok. For a while though, thought I was going to get the tech to make a house call.