A few years ago, my KIPASS ignition switch did the typical song and dance on my 08. It was under warranty, so they replaced it. I didn't give much thought about it until just the other day it started to do it again. I'm creeping up on 100k miles and my warranty expired back in May, so I knew I was on my own here!
I looked through the forums for remedies and saw some had sprayed carb cleaner in the nooks and crannies. That made me nervous, but I tried a reasonable amount, all to no avail. So, with not much to loose, I decided to take the ignition apart and attempt a self repair. There are a few short YouTube videos on line and Fred H. has some good pictures, but there were no detailed instructions.
After removing the top clamp and unplugging the two KIPASS connectors, you must drill out the heads on the security bolts on the bottom. Once that is done, you can remove the ignition system and use vice grips to unscrew the remaining bolt portions from the top clamp. There's at least a quarter inch sticking out, so there's plenty to get a grip on. Most of the screws on the assembly are security screws. You can get the correct socket set for cheap at Harbor Freight. Three security bolts on the side allows you to remove the panel covering the solenoid that releases the key to rotate. My solenoid area was very clean, and I just used that access to allow me to rotate the key as I was working and lubricating the assembly. I've not heard of that solenoid ever being an issue. There is a Philips screw on the bottom and two on the top that allows you to remove the tall, slender box that houses the actual switch that is the offending culprit. Looking from the top, there is a tang that sticks out from the ring that contacts a plastic button when you push the key down. That button is what gets stuck.
Once that long box is off, there is one small Philips screw that allows you to remove the plastic button, spring, and switch (it's a small version of a brake light switch). I lightly sanded the sits of the plastic button (it's square in shape) and used graphite powder to lubricated it. There was quite a bit of dust and funk in that area.
Reassembly is reverse, as usual. I used two metric bolts to replace the security bolts that I drilled out. I'm not worried about theft. If someone wants to disassemble my bike in order to steal it, then they need it more than I do. Before putting it back on the bike, I plugged it in to verify it worked...and it did!!! I gave the whole lock assembly a good graphite bath and made sure to clean the contacts from the bottom access plate where the switch panel is.
So, in short, it's quite doable to disassemble the ignition and clean it up to prevent this problem. I would only do it if you're not under warranty. I didn't take any pictures because between Fred H. and YouTube, you can easily see the parts I've described. Hopefully this helps.
