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Two_seasons
Posted on Saturday, June 18, 2011 - 04:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

So I'm installing the new ignition switch from American Sport Bike and have questions.

I've noticed that the #33 connector has a heavier gauge wire on the female side (bike side) than it does from the male side of the connector to the ignition switch, new or old design. Why would Buell use heavy gauge to the #33 connector, then same size wire gauge for all three legs on the other side of the connector? Doesn't compute!

Also, the screw-on bezel face for the new switch only get threaded on less than a full turn. I could relieve the back side of the dash to give me more thread, but then the dash is weakened. What did you do when you installed the Drag Specialties switch to get more thread through the dash hole?

Finally, there is no removal of the key when in the "park" position of the new switch.

I'm going to splice the wiring from the ignition switch into the connector to match the original Buell legend---OFF---PARK---IGNITION and leave the original Buell legend intact.

Thanks to all.
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Jramsey
Posted on Saturday, June 18, 2011 - 08:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

http://www.badweatherbikers.com/buell/messages/476 23/635060.html?1307473444


"Finally, there is no removal of the key when in the "park" position of the new switch."

Nope, why would you want the leave the "park" lights on ?
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Xl1200r
Posted on Monday, June 20, 2011 - 12:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Would this switch also fit an S3? It's not listed in the S3 section. Mine acted up one night after filling with gas - turn to on and it was like it was still on "Park". Did it probably a dozen times, then it worked and hasn't had a hiccup since.

I do also get a very intermittent cut out of the engine. I thought it was wires, but it's totally random. Happened a bunch once after I washed the bike, then only two or three times after that (over a year ago now).
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Kalali
Posted on Monday, June 20, 2011 - 12:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I removed a little material from behind the dash to allow for more turns on the bezel. Did not seem to compromise the strength of the dash. Just enough to give a couple more full turns. I suppose you could also (gently) remove some material from double-D portion of the switch but I did not find that necessary. As for the wiring, I honestly did not notice the difference - just spliced them to match the original switch pattern. Been working fine since.
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Two_seasons
Posted on Monday, June 20, 2011 - 01:42 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

One of my original questions hasn't been answered.

Why is there a different gauge wire on the bike side of connector #33? Ignition side of #33 connector, both new and old, doesn't support the heavier wire (all the same size). I'm confused.

I also fired up the 99 X1 Lightning I have. If you recall, I've got some ~ 3500 rpm cutout, occasionally, going on with that one. I did the ignition switch "feel test" and this one is running red hot too.

If I took this new ignition to a locksmith, could they key it to my original Buell key?

Finally, any problems you know of with wiring the new switch per the original Buell legend on the dash? Internally, are the contacts for PARK and IGNITION the same size?

(Message edited by two_seasons on June 20, 2011)

(Message edited by two_seasons on June 20, 2011)
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Kalali
Posted on Monday, June 20, 2011 - 03:43 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

"I did the ignition switch "feel test" and this run is running red hot too"

So you're saying the new switch feels red hot even through thick black shrink wrapped style plastic cover on the back of the switch? If so, you must be having another issue. Mine hardly feels warm if I hold it with three fingers. On the old one I could only hold it for a few seconds before getting blisters on my finger tips...
Again as for wiring, I just switched the position of the IGN and PARK wires before splicing them into the main harness. This maintained the original Buell legend on the dash. Don't recall hearing anyone mentioning anything about the difference in wire gauges. I'll take a look later just out of curiosity to see what you mean.
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Two_seasons
Posted on Monday, June 20, 2011 - 10:31 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Kalali:

No, I haven't installed the new switch in the 2000 X1 Lightning yet. I only bought one switch so far.

I was saying that the 1999 X1 Lightning that I own is doing the same thing, the ignition switch is running red hot and will blister your fingers after a couple of minutes.

Both of my X1 Lightnings have running issues.

The 1999 "coughs" at about 3,500 rpm once in awhile. On a 25 minute commute to work, it might do it 1 time. Or not.

On the 2000, it acts as if the plugs are loading up, then will run good for several minutes, then do it again, and again.

These X1's both have the original ignition switches and I can't believe that the heat out of the switch is the sole problem. Last November I picked up my '99 out of MN and was running in air that was about 38 degrees F. And it still "coughed" now and then during the 350+ mile trip to my home.

But, I do believe that the HD original ignition switch is poorly designed. I'm not sure why at almost 18K on the '99 and almost 11K on the '00 that these ignition switches would not have exhibited this behavior with the prior owners. I was only able to talk to the '99 owner after purchase, the '00 was bought via a dealer.

I'm going to install the new switch, wire it to match the original Buell dash legend, and see what it does.

Thanks guys. And I'll post back and let you know if the new switch does the trick.
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