There was a multitude of electrical problems with my 96 (not 93 Dumbass PO) k1100lt. Including complete intermittent electrical power loss while turning the handlebars, partial accessory power, the dash light would flash on every once in a long while, etc...
I suspected one of the large wire bundle plugs under the tank coming apart or experiencing some corrosion. No such luck. However, it was apparent that someone had been in there before as the bundles had been unceremoniously crammed back in place.
I found a mess of wire bundles that, when moved a certain way, would cut the ignition power. I started separating wire bundle bindings around the intermittent ignition power and narrowed it down to the 5 wires as they entered the ignition switch.
Thank You Dr. Duck for the instruction as to how to extract the ignition switch BTW.
That ignition switch had been failing on so many levels.
* I had not been able to utilize the steering lock function.
* Many of the Key Lock Wafers were so fouled up with gunk that they were not closing.
* The Wafer Springs had become "compressed", probably due to the gunk holding the wafers down.
* The wafer that held the lock in place was jammed. I am lucky the ignition didn't just fall out.
* Two out of the Five wire were completely severed, including the red power wire.
* One wire was broken under its insulation.
* I found at least one contact slider that had not been making contact in the slider housing, so I serviced them all.
I know that I could have just bought a new/used ignition switch, but where is the fun in that? As it is I spent 7+ hours on this project from start to finish and accomplished;
* Total Key Lock Service, stretched the springs, wet sanded the wafers acetone/Air Compressor/Jeweler File out the Wafer Channels and drilled out a "dent" fouling the Cylinder Stay Spring Channel. Lubricated appropriately.
* Removed, repaired and re soldered all 5 wire connections. Tested for beaks and continuity.
* Cleaned and serviced all the contacts in the slider housing. Stretched all 4 springs and evened up the contact points. Tested for continuity.
* Added to the "Mental Map" of the wiring schematic for this bike.
* Solved 90% + of all my electrical problems in one fellswoop.
* A Sound BitchSlap to the Backside of the Ignition switch
BooYaaaah !
