I removed the ignition switch per the instructions given on this board in order to adjust my handle bars on an 08 SG. That went smoothly. However, putting things back together is proving to be a nightmare. Now in order for me to lock the steering (by pushing down on the switch when in the locked position) I have to press down very hard on the switch. The reverse is alss true, if I want to unlock it I have to pull quite a bit on the switch to make it rise away from the handle bars. Yes the spring was put back on, I tried many combinations of the "fittings" and they only fit in one sequence and order. I put some WD-40 and nothing seems to help. What did I do wrong. Thanks.

 

You did it yourself. It became a nightmare. Some touring models had a recall on Ignition switch. See if you qualify.

 

You didn't get it back in right. Take it back out and make sure the splines are aligned properly. One set of grooves is square and the other is dovetailed. You have them turned around wrong down in the switch. Don't ask me how I know...

 

How do you align the splines. I looked down the hole and it is hard to see what is squared and what is dove tailed.

 

Thanks for all of your inputs, I finally figured it out.

 

Yeah, so how did you do it?

 

HOW DID YOU DO IT BRO???????????? The world wonders!

 

Once you git the switch aligned and working well. Find you a Harley Dealer that carries Tri Flow Spray and use the plastic nossel that comes with the spray and spray some of this down into the keyhole. It will help displace water and has teflon to cut the gum and cut wear. Been a locksmith since 69.
You don't realize when you wash yer bike and ride what all gits in the switch. It needs lubrication often with a good lubricant.

 

Bascially, I used a small flashlight to shine down the hole. Then I took a regular screw driver that was wide enough to fit between the splines. I turned the screw driver one 'click' at a time and looked down the hole after each turn. Once I saw that all the splines were aligned, then I insereted the switch. I figured I had 50/50 chance of getting it right the first time, and sure enough it was not correct. So, I contnued turning one click at a time for another 180 degrees untill all splines aligned again (you can tell they are aligned by the fact that the two sets splines are in line with each other). Instered the switch, and easiliy went into the locked position. Pretso.

 

Service manual & T-handle Ignition Alignment tool makes the job easy.