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Rebuilding the RSV Ignition Switch

  Author: Peter Behm
  Views: 20147     Votes: 19
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Thought I would show a few shots of how the ignition switch is put together on these bikes. I know there has been a lot of posts in the past talking about people getting stuck with two different keys after having the switch replaced. It is actually very simple to use your existing key while getting the new contacts for the switch.

Here is the whole assembly.

If you remove the two screws in the next picture this will get you into where the contacts are that need replacing when the switch fails.

Here is what you have when the two pieces are separated.

Now in order to reuse your current key in a new switch you would take your old and new switch apart as shown in the third picture and then pull this contact from your old switch.

and switch with the new part. It just slides out and has a notch on the back side that it fits in. Now just reassemble your existing cylinder onto the new base and you are all set.

Another thing that I have read in the past is that lubing where the key goes in will help lube your contacts and make them last longer. I do not see this doing anything but lubing the pins in the cylinder and getting your pocket dirty . If we look past the upper set of contacts you can see a little bit more of how the switch is built.

As you can see the piece in the bottom of the picture gets screwed into the assembly (pretty much sealing it off) and is taking the rotation of the cylinder and transferring it to the contacts. The key cylinder itself is still down in the bottom of the assembly and there is really no way for any lube to make it to the contacts. Here is another picture showing the bottom of the switch.

Hopefully this might help someone out in the future.

11/5/2007 TAC Update

To remove the ignition switch from the bike, it is necessary to remove the tamper-resistant (rounded head) bolts, shown in picture below. Center punch the bolts, then using a sharp bit, drill the heads off the bolts. Remove the switch and then remove the remainder of the bolts with pliers. An alternate method is to use a dremel tool to slot the heads of the bolts, then use a screw driver to remove them. New bolts will be required to reinstall the new switch.

Original post 11/15/2004

Last update: 05:39 PM Monday, November 5, 2007

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