My ignition switch refused to unlock the other day. No matter what I tried, (for 1 1/2 hours!) it wouldn't unlock from the locked position. I finally went to my service manual (DUH!) and learned how to remove the ****. The **** has the locking part built into it. The fork lock and ignition switch are turned by a long stem that goes into the switch housing.
After removing the **** I was able, after a couple of trys , to get the **** back on in an unlocked position. Tried locking it again, jammed up again.
Soooo, took it to the dealer. No matter what he did, couldn't get it to repeat. Worked like a charm. Finally the tech found a problem in the depth the key would go in. It can travel past the lugs in the ****. So they agreed it was defective and are ordering a new ****, which has to be cut to my keys.
Anyone else have this issue?

 

I have not had this problem, yet. But, have read that other have had this problem.

 

What year bike are you on Greg? Just wondering if this is something I need to look for.

 

There is a service bulletin on this for earlier models, not sure what years but I think it was up through 06, or partial year 06. Had my own horror story with a failed switch, I wasnt covered by the bulletin cause I messed with it and broke something that wasn't covered when I took it out.