Main Switch Replacement

[dna9656]

The Original main Switch is riveted in place. Anyone ever remove the Main Switch before? If so can you tell the forum about it?

[Father Pobasturd]

Are you talking about the key switch? It's held on with breakaway bolts.

[dna9656]

Yes, the key switch; Yamaha calls it the Main Switch in all the manuals I have seen. It looks to me like rivets hold it in place, have you changed the switch, did you break the "breakaway bolts to get the switch out? If so what did you use to secure the new Main Switch in place?

[Shores]

What is the problem with the switch? If it’s just not turning with the key or not releasing the seat, I suggest you lube the key slot with graphite and the seat release cable with a dry lune to see if things free up before you go to the expense of replacing the switch.

[dna9656]

The switch will not turn to the on position, have lubed with everything I have including graphite, the seat cable moves freely and is lubed as well. the poor thing is just worn out I'm afraid. It used to work intermittently; now it intermittently works.

[davej]

grind the bolt heads off to remove. Once you get it off there are a couple more bolts to remove to get the tumbler section out. Once you get that out insert the key, you will see the tumblers retract flush with the tumbler body. You will also see 1 or more brass tumblers that are sticking out past the body. File them down even with the tumbler body the same as the others. turn the key and it will be free to turn when it is filed down far enough. reassemble using regular bolts and the repair won't cost you even 1 nickel.

[dna9656]

Thanks Dave!

[dna9656]

I retrieved my Main (Ignition) Switch today from Partszilla; I got it installed and changed the plugs while I have the fuel tank back. The seat latch still doesn't ENGAGE the seat, I have put washers under the seat side to no avail, the hook side is so worn its on a hair trigger to lock the seat in place, I think I need to order a new latch....
Honest; when I bought this bike I thought it used 2 spark plugs so I changed TWO. Can you guess which plugs are the older ones? The electrodes ALL looked the same, squared off and the ground wasn't worn away at all!.

[DEEPHATE]

I just put a new latch on mine. It's great! I fought with mine for years..

[dna9656]

Well I'm glad it's done!