How to replace the ignition switch
How to replace the ignition switch
Introduction
This article describes how to replace the ignition switch on a Ninja 250. Typically, this will need to be done because some dunderhead had to discover for himself that you really can't steal this bike by jamming a screwdriver in the lock.
The procedure is fairly straightforward. You'll remove the top triple tree, drill off the security bolts, bolt on the new switch, and put it all back together. This even works with the fork lock engaged. If you have all the tools together, and a reasonable working environment, it shouldn't take more than about 2 hours. Add time as necessary for getting parts or tools.
Tools Required
In order to replace the ignition switch, you will need the following tools:
- Large crescent wrench (10-12")
- Metric hex key set
- #2 Phillips screwdriver
- Electric hand drill
- 1/4" to 3/8" drill bit
- 10mm socket
- Socket wrench
- Pliers
- Clean rags
Depending on your exact situation, you may need one or both of the following tools:
- Screw extractor
- Vice grip style pliers
You will also need the following supplies:
- 2x M6x16 bolts (see below)
- Red thread locking compound (high strength)
- Blue thread locking compound (low strength)
Security Bolts
A quick word on security bolts. Kawasaki installs the ignition switch with two fancy bolts, which have a snap-off section. They're installed using an inverted Torx driver (the Torx bit is on the bolt, your tool needs a Torx shaped cavity). Once they're tightened down (or perhaps as they're tightened down), they're broken off, leaving a smooth face with no grip for any tools. At least on a 2006 bike, these bolts are glued in with red thread locker, and are essentially impossible to remove without destroying them. Earlier bikes reportedly have no thread locker, but we have no good data on when this change was made.
You don't have to use new security bolts. There are several reasons for this, but the most compelling of them is that an inverted Torx tool is going to be damned hard to find. On top of that, these bolts are all but impossible to see on the bike, and it would take a truly dedicated thief to give them a go, even if they're normal hex-headed bolts. Since the vast majority of would-be thieves who break ignition switches are apparently as intelligent as a shovel-full of dung, it's probably not worth the trouble.
If you elect to use normal bolts, you want two stainless steel metric 6x16 socked-headed cap screws. These are available at some hardware stores, and any fastener specialist will have them. Lowes carries black oxide bolts, but these will rust in short order, so stainless steel is vastly preferred. Expect to spend about a dollar on a pair of bolts. Security bolts are 88 cents each from Ron Ayers.
