Key/Ignition switch 2011 K9 250

[BDC80538]

I replaced the key switch on my big dog with one from, big dog parts king. New switch tested fine before mounting to cover. Once installed turning on became intermittent while turning key on and off. I would get just a flash of light on and quickly off on the speedo while turning the key. Took it back off, I removed the switch from cover and it worked fine. Put it back in, same issue. I could get it to work by lightly forcing the key one way or the other but the problem still exist. any ideas?
Thanks!

 

[Jersey Big Mike]

test the connection by shorting the two wires together and see if it works reliably first (eliminates downstream issues)
With battery disconnected connect switch and check for proper operation somewhere PAST the connector on the new switch.
Small pins can be used to penetrate the wire if you can't find a test point - If you do this I recommend using some spray electrical tope over those spots afterwardsto be certain of watertightness.

 

[Mickmorris]

I replaced the key switch on my big dog with one from, big dog parts king. New switch tested fine before mounting to cover. Once installed turning on became intermittent while turning key on and off. I would get just a flash of light on and quickly off on the speedo while turning the key. Took it back off, I removed the switch from cover and it worked fine. Put it back in, same issue. I could get it to work by lightly forcing the key one way or the other but the problem still exist. any ideas?
Thanks!

I would give Eric a call & see what he thinks. That’s very strange that it only malfunctions while in the cover….

 

[Jersey Big Mike]

I would give Eric a call & see what he thinks. That’s very strange that it only malfunctions while in the cover….

it indicates that the problem is not likely the switch mechanism itself but something near it (connector etc) in the setup. Although a bad switch is possible.
When you tested it was it with a digital or analog meter -- digital meters can miss quick disconnection where you will see the needle move on the analog.

 

[BigDogRick]

The switch is a simple circuit connector. On -off. You can replace it with a toggle switch - it's that simple. I rode for 5000 miles one year with a toggle switch I picked up in S Dakota at a truck stop on my way back to Michigan from Sturgis. It even lit up when in the on position. I loved it but, alas, some level of security is essential if even for only the psyche so I replaced it with a tractor key switch.

 

[Rottweiler]

Sounds like a ground problem.