This is a spare machine so spending $160 for one of these switches is unacceptable.
I replaced the handlebar switch with the switch leftover from converting my 2012 to the international handlebar switch. This switch mated with the existing plugs with no changes and all functions worked. $0.00
If you have to buy it new it’s about half what the original switch costs. You can probably find this switch used in decent shape too.
I’m still going to need a START switch that’s not a butcher job…
So I says to meself… What about using a $54.00 2002 Key switch?
The 2001 key switch has 4 terminals.
The 2002 key switch has 6 terminals.
The ignition key switches use an unsealed Delphi Metripack 280 plug and terminals that are very cheap. Delphi PN Six Positon Plug 12092254-B with two Terminals PN 12034046-L. I have the terminals in my goodies already and Mouser stocks the plug.
You’ll need around 4 ft of SXL jacketed 18ga automotive wire, 2 terminals, and one plug. I would suggest buying at least 10 terminals… $0.29 US each from Mouser Electronics ain’t going to break the bank.
The key switch terminal positions are labeled A-D (4 term) or A-F (6 term)
2001
A & B are ON
C & D are OFF
2002
A & B are START
C & D are ON
E & F are OFF
Extract the terminals and move each wire from the four position plug to the six position plug one at a time;
4 –> 6
A –> C
B –> D
C –> E
D –> F
The wires for the starter solenoid in the new six terminal plug positions A & B will need to be brandy new. Properly strip and terminate one end of your new start wires with the new Metripack terminals and insert the colors you want in A & B of the new six position plug.
Position A on the six position plug attaches to the WHITE wire with RED stripe that runs down to the starter solenoid. It’s off the old handlebar switch in position C of the plug furthest away from the rider.
Position B attaches to any ignition power wire… RED wire with WHITE stripe.
I used White with a Red stripe attached to the WHITE/RED START wire and Orange with a Red stripe attached to the RED/WHITE power because I could add the tracer stripe colors with a sharpie. Use whatever wire colors you want…
I highly recommend using Cross-link Polyethylene jacketed Automotive wire (SXL, TXL, or GXL). You can use PVC jacketed automotive wire but it doesn’t stay flexible and lets more moisture through. Whatever you do don’t use lamp cord or speaker wire.
I spliced the wires together using size 16 Deutsch DT terminals and adhesive lined marine heatshrink.
This looks and works as if it came from the factory setup this way.
Get the wiring diagrams for your machine and verify everything before you begin…
