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About a week ago I decided to change the fork oil on my 09 ultra classic. While pulling off the plastic panel under the ignition switch (after removing the switch) I managed to break the ignition housing. I ordered a new one on sale. The local Indy wants an hour and a half labor for the whole job. I managed to get the old one out with a bit of jimmying. The new one comes in tomorrow and I'd like to install it myself to save a few bucks. The old one was a bitch to get out and I'd like to not break the new one getting it back in. Does anyone have any hints or tips for me?
I'm assuming you don't have a service manual for your bike?
yes, I do. I have 3 in fact, but none of them goes into specifics on how to remove or install the ignition housing unit. They generically say to remove it. It's wedged in there and I had to twist it to the side to get it out. Had it not been broken already it would've broken at that point.
However, the online Harley manual has you remove the entire fairing, radio, and fairing cap. According to my Indy, all that isn't necessary. Maybe I should just save myself the effort and have him do it.
Last edited by sabunimwil@gmail.com; Nov 18, 2019 at 06:54 PM.
I didn't have any trouble when I changed mine. I didn't take the outer fairing off. I just removed the plastic panel below the switch ****. I made sure the fork lock wasn't engage and removed the two screws securing the switch housing. I pulled the housing up and back a little. This gave me enough room to remove the wiring. Good luck to you.
I didn't have any trouble when I changed mine. I didn't take the outer fairing off. I just removed the plastic panel below the switch ****. I made sure the fork lock wasn't engage and removed the two screws securing the switch housing. I pulled the housing up and back a little. This gave me enough room to remove the wiring. Good luck to you.
During my restoration, I had an intermittent electrical issue that led back to the switch. I pulled it out several times and disassembled it looking for the problem before finally replacing it and the system harness mating connector. I have removed and installed the switch both with the fairing and radio in place and without. While it can be removed without removing the fairing and radio, I personally found that it is much easier with less opportunity to get Murphy'd if you pull the fairing and radio and I did not see any time saving advantage by leaving them in place. Yes, it can be done, and I am sure that a professional has learned many tricks and work-around techniques that I do not know. I was successful doing the task both ways but, based on my limited experience, I would not advise doing it without pulling the radio and fairing if you have never done this before. New switches are not cheap.
Last edited by skinman13; Nov 19, 2019 at 09:52 AM.
I got it installed without breaking it. Yay! And i did it without removing the fairing and radio. It took me about 2 minutes of fiddling with it but it just dropped into place all of a sudden and I screwed it down with the stock screw's. Put the panel back in place, dropped the ignition in, and it fired right up.
I should've made a video of it and youtubed it. I found one video of it being replaced on a road glide but not an ultra classic. They are two different animals.
Great video!....even though I probably wouldn't do it myself (cause I know I'd "F" it up).....lol. But IF I were to give it a shot I'm sure I'd buy that specialized tool he demonstrates. If the tool works it completely eliminates the need to remove anything other than the chrome switch ****.......well worth the "crazy" cost of the tool ($35 on Amazon).....
Great video!....even though I probably wouldn't do it myself (cause I know I'd "F" it up).....lol. But IF I were to give it a shot I'm sure I'd buy that specialized tool he demonstrates. If the tool works it completely eliminates the need to remove anything other than the chrome switch ****.......well worth the "crazy" cost of the tool ($35 on Amazon).....
That tool is worth it if you have had to do more then two bikes. Bought mine from Georges garage. Long ago.
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Ignition housing broke
