I've watched the youtube video clip a bunch of times and he makes it look so easy. I didn't make the homemade tool, but just used a paint can lid removal tool. It worked fine to unlock the forks. But now I'm trying to re-install the switch and I can't get it to go down all the way. I turned the forks back to the lock position. But the switch doesn't seem to algin correctly. Hopefully this makes sense. What am I doing wrong?

 

Same thing happened to me. I used a screwdriver. Finally got a flashlight and looked down in there and lo and behold its like there is "multiple level plates" down there. I had rotated some but not all of them. Look at the bottom of the shaft that you insert in there. It has like a "T" shape to it. One side is straight and the other side is wedge shaped. Same with the holes on the "plates". They have to all be on the same side. Sorry for the bad part descriptions don't know the proper terminology. Hope this makes sense.

 

that's the thing with the "tool" it can contact multiple plates all the way down, a screwdriver or tapered tool may only contact some.

a bent piece of copper pipe will do it

Mike

 

Yep...it's like a puzzle & every piece must lign up. Look in the hole & you'll see.

 

I used a screwdriver. Sounds like I got lucky. Will make the copper tubing tool next time. Good luck MichiganRider.

 

Thanks guys! I looked down there and it was hard to see. So I should make the tool and turn each level the right position till I get to the bottom? Anyone know what size copper tube to use?

 

You can buy the tool from here for $25 if you don't want to make one

http://www.marcparnes.com/HarleyIgnitionSwitchTool.htm

 

1/4" copper 8" long...flatten & bend other end to use as handle.

 

Thanks everyone! Looks like I'm making the tool tomorrow.

 

Here's the tool I made... Obviously, just flattening a piece of tubing is a little easier and probably works just as well, but I wanted something a little more robust and permanent.