Sounds like good advice lp. It turns out that the 05 switch and the 09 in the video don't remove in the same manner. Instead of removing it from the full lock position, the 05 requires you to put the switch in the accessory position and use a small screwdriver to reach the button.

 

Put key in and turn a little past lock to press button.
Ooops, glad ya got it lol.

 

my 05 removed from the acc. position ,, I got it miss aligned in the process of doing my repairs and just used a long screwdriver to re align it and it worked for me

mike

 

Yeah, that's what my manual says too. Did you disconnect the battery ground before you removed the switch?

 

don't remember ,, but I don't think so as I was just changing the ing. switch cuz I broke the top of it off (don't ask)

mike

 

I'll echo what LP said in Reply #10. I've had my 2007 FLHX's ignition switch **** out probably 20x and never used an alignment tool. It can be removed in any position (off, acc, etc.) but must be reinserted in the same position. Forks can be moved around freely but I would avoid getting it too close to the fork-lock position (full left), as that may cause problems (never tested it but have heard warnings). BTW, a small screwdriver isn't necessary to flip the button under the **** if you have small fingers, as I always just used my pinkie.

I did get mine out of whack once when not paying attention and forgetting to install all the plastic and metal spacers first, then turning the ****. Once the tumblers were out of alignment a large-blade screwdriver got them back in place rather easily.

 

Flat Blade Screwdriver works perfectly fine if you accidentally get the internal parts misaligned. However, if you remove the I.S. correctly, and not turn the forks or anything, you shouldn't need a tool at all....just a tiny screwdriver to press in the lock on the underside. Good Luck.

 

Don't need a special tool. You can line it all up with a screw driver if need be.

 

I made mine, I felt the copper was too soft and flimsy. Bought some aluminum stock at Lowes, took measurements of the ignition switch and went to work.

 

I used 5/16 brake line and it worked.