‘18 Ultra Limited

Changing handlebars and made a dumb move and now I’m kinda stuck

i had removed the ignition fork lock as per manual and all was good. Then I made the mistake of turning the bars to check some figment issues and then I heard it.....click....and now the forks are locked. I knew better.....but at that moment I wasn’t thinking about the consequences of turning the bars.

I grabbed the ignition lock and dropped it back in and it seemed to go all the way in, but maybe too far as I didn’t place the spring back on to the ignition lock. But it slid all the way in leading me to think nothing is out of alignment.

I probably moved it around trying to unlock the forks with no luck, but then remembered about the spring. Put the spring on, dropped the ignition lock back into place and was able to get the forks unlocked. Excellent! I was ready to buy the alignment tool off Amazon but now I figured I just got lucky and won’t need to buy it.

But now that the forks are unlocked, I cannot get the ignition fork lock out. I did a quick forum search but was not able to locate any threads about this.

Any suggestions or insight as to how to get past this dumb mistake?

i’d like to just keep working on it and hope that it will eventually release out, but that doesn’t seem likely right now and I don’t want to make matters worse if there is a process to get past this.

Thanks for the help. Feeling a bit frustrated at the moment ☹️

 

The ignition tool is a good investment for such issues. Without, you can line them up by fashioning your own tool or using a screwdriver. Look at some YouTube videos on the subject and it is demonstrated.

 

thanks Dawg.

I agree with you but my problem is that I can’t get the ignition fork lock out.

Something is outta whack and I really don’t want to pull the ignition and disassemble it.

Hoping someone can tell me how to get it out now that I’ve managed to get it stuck and can’t remove it. Got the bars unlocked, but now I can’t get the ignition fork lock to come off.

 

Ahh, sorry I misunderstood. I thought you had the tumblers out of whack but the ignition was out. Have you tried finessing the key in the lock and then pushing up on the tab underneath again? And/or pushing the bars farther toward the lock position while doing the former?

 

I've done this a couple of times. Probably every time I take the ignition lock out. What worked for me is to look at the instructions and keep trying to pull the lock out. Turn the bars a couple times, try again. I don't know exactly what "fixed" the problem because I'm usually frustrated and trying anything to get it out, but it always came back out and once I put it in properly problem solved. Maybe the indent pin under the cover isn't releasing?

 

Yeah, when everything is going normally it can be difficult to get the ignition lock out, so when things go a little wrong it isn't any easier. I've had times when the lock comes on right away, and times when nothing would seem to work.

If you haven't already, I'd disconnect the battery ground before doing much more. And having the alignment tool is important for when something like this happens. Then take a break, have a cool drink and read the instructions again and give it another try. And as mentioned, you may need to rock the handle bars back and forth a little. But if it still won't come out, take a break from it and try again after some time.

Paul

 

Take the entire switch off the bike. Remove the two allens at it's base and remove the power cable and it comes right out - super simple. Then you can work on it on a table with good lighting etc.

When you get it on the table you'll see it's simple to disassemble and fix the issue - which is probably just one of the tumblers is 180 out locking the shaft in place...

Great video on how to disassemble and realign it with one caviot: at 12:32, the wave washer goes on top of the silver cylinder, not between the electrical switch and black mechanical switch.

 

I have played with it some but still no luck. I’m pretty sure the indent pin is releasing but I have not turned the bars any. I’ll give that a shot tomorrow because I’m certainly frustrated today.

I can get the fork lock to turn into all positions but I just can’t get it off

 

thanks Paul

i pulled the main fuse but have not disconnected the battery.

I’m gonna move the bars around and keep trying.

Hopefully by removing the main fuse I’ll be OK but disconnecting the battery definitely seems like a good call at this point

 

It's been a long day for me and I'm tired, see if this helps ya any


WP