I installed a new stock-style ignition switch on my bike, and it's quite difficult to turn. It has big brass **** on the underside which create detents for the various switch positions. What's the best method of easing the actuation on this style of switch? Should I be thinking about sanding the crowns of the **** a little smoother? Or is there something else people have found that reduces the effort a bit?

I understand you don't want the thing vibrating out of [x] detent you've chosen, but it doesn't seem like it should be that hard to turn the switch. I thought it'd work in and get easier to turn, but no dice.

 

I had the same issue with new OEM Harley switch . I coated the terminals with lithium grease , much easier now . But it will collect dust and require maintenance down the road.

 

That switch comes apart and all of the bits inside can be cleaned. Pull up on the center rod and remove the barbell. it all comes apart after that. Take pictures so you put it back in the correct order. You will be surprised how much corrosion and junk is in there.

 

2 things cause that dry assembly is one but usually its the hole in the dash is making contact with the outer cover of the switch < how to check to see whats up

remove the dash top - turn switch if its fine mod the dash cover hole is the easy way to get it to work - now you may have to deal with the chrome edge but nail polish in clear is your friend

 

Since it's a new aftermarket switch, it may have been assembled dry. For things like that I tend to use a dry lubricate, like graphite, to avoid dirt buildup over time.

Paul

 

Like John said. Stiff switch dragging on the dash cover.

 

Thanks, Gentlemen. I have been wanting to apply some weatherstrip adhesive to keep the rubber trim from wiggling loose from the lower edge of the dash, so will R&R the switch and try all of the above. Much appreciated.

 

Okay, tried reliving the hole in the dash a bit--which may have helped, as it was extremely close if not touching the switch's O.D. Then put some dielectric grease on the 'barbell' and brass contacts with a Q-tip... Shazam! Now the switch works like it should.