noticed since then that the ignition switch is 'glitchy'.
been a cpl days and still happening.
Problem with these switches is Lucas didn't really intend 'em for the location first NVT (on the T160 and electric-start Commando) and then the Co-op ('79-on twins have the T160 bits) used 'em.
This is a new ignition switch, installed in March.
As with almost anything sold new in a green box with "Lucas" on it under the "Genuine Lucas" banner, it's Wassell so ...
I still have the original
While the ignition switch in use might "dry out", I suggest it's got internal problems already and you could do with pre-empting its possible death by rebuilding the other switch
, especially if it really is "original" (as opposed to an older replacement?).
Is there a rubber cover on the switch?
the new cylinder sits just a bit taller and the rubber doesn't come all the way down to the bezel. There is a small gap about 1/4" where water could enter the bezel or switch.
This isn't clear:-
. In what way does "the new cylinder sits just a bit taller"?
. Is your bike using "rubber cover" 60-4335:-
... (with the moulded slot cut for the key) over the 97-4589 "Ignition switch nut"
If so, the narrower diameter of the "Ignition switch nut" should be screwed down to the "Panel", that has the idiot lamps and covers the top of the "Switch box" between the speedo. 'n' tacho. The "rubber cover" fits over the wider uppermost part of the "Ignition switch nut" and a lip moulded inside the "rubber cover" keeps it over the "Ignition switch nut".
So I'm wondering what you're calling "the bezel" and where this "gap about 1/4" could be?
Try an O ring on first.
This could do with some clarification - where's the O-ring supposed to go?
Originally Posted by Rancidpegwoman
Stuart’s advice on drilling these switches to let the water drain out,
Drill a small hole in the terminals end of the switch, at what'll be the lowest point when the switch is mounted on the bike.
However, it should be additional to trying to prevent water getting into the switch. If your bike does have the 60-4335 Cover and 97-4589 Nut, there were better parts fitted '81-on:-
. 97-7120 Nut (the "Cover" is retained by the Nut and clips over it when the ignition key is out of the switch):-
. 97-7123 Cap fits over the ignition key and clips over the "Nut" when the ignition key is in the switch):-
... if this has a problem, it's that the ignition key "Cap" is quite lumpy, doesn't sit well in a pocket; also, you have to make a hole in the "Cap" to match up to the hole in the key for a ring or whatever.