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It seems as though my 2011 Ultra won't start (not even a click). Plus the fairing indicator lights and headlight does not turn on. Both the battery and the MAXI fuse test out good. I believe the problem is at the ignition switch housing. I'd like to remove the ignition switch housing and according to the HD factory service manual one needs to use a specialty tool (HD-45961) to remove the switch connector. What are people using if they don't have this specialty tool?
I made my own, but there are several YouTubes on this. Ryan Uhrlacker has a video that takes the whole assy apart to re-align. You shouldn't need the tool, but it makes it a little easier.
I made my own, but there are several YouTubes on this. Ryan Uhrlacker has a video that takes the whole assy apart to re-align. You shouldn't need the tool, but it makes it a little easier.
Strange, I haven't seen any videos of this. You are talking about the "Ignition Switch Connector Tool" and NOT the "Ignition Switch Alignment Tool"?
FWIW, the ignition had to be replaced on my '07 several years ago when it went bad on me out at Sturgis. I could make it work only by applying significant upward pressure on the switch (toward the fairing), so I did just that, with duct tape, to get me to Rapid City HD. I lost ALL power on the interstate.
The alignment tool differs from the connector tool.
The connector tool is used to release the electrical connector from the ignition switch. From what I've read, a small flat blade screwdriver will accomplish the same.
From what I've read, a small flat blade screwdriver will accomplish the same.
I tried a variety of different sized small flat head screwdrivers and I couldn't get the connector to release. I ended up just ordering the tool from George's Garage. I called a few of the local HD shops to see if they had the Ignition Switch Housing (71572-06) in stock. None of the four dealers near me had it on the shelf, so I just ordered it. Parts counter guy said normally the parts arrive in three or four days, but due to the Covid-19, parts ordered may take a couple of weeks.
Most of my screwdrivers were either too short to reach or too wide to fit inside the plug housing.
I took a thin steel rod about 18 inches long, flattened the end with a hammer then just used my bench grinder to take off excess on sides so it would fit into the housing.
Maybe it will help someone else, but it is always nice to have the correct tool.
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Received the tool today from George's Garage. Using the specialty tool, I was easily able to pull out the connector. I've attached a couple of pictures to show what the cable connector and the connector in the ignition switch actually looks like.
The next issue I am running into is that I can't seem to remove the ignition switch. There doesn't seem to be enough clearance under the handlebar upper clamp. Do I need to remove the handlebar upper clamp to get enough clearance? The factory service manual doesn't mention the need to do so.
It seems as though my 2011 Ultra won't start (not even a click). Plus the fairing indicator lights and headlight does not turn on. Both the battery and the MAXI fuse test out good. I believe the problem is at the ignition switch housing. I'd like to remove the ignition switch housing and according to the HD factory service manual one needs to use a specialty tool (HD-45961) to remove the switch connector. What are people using if they don't have this specialty tool?
Ignition Switch Connector Remover Tool
