I noticed sometimes would not turn on the lights for the gears and sometimes refused to crank over and the key would not turn it off.
Took apart both switches and cleaned and greased and all are good again. This ATV had sat for about 5 years.
For starter switch used some 0w-40 oil poured into the backside of the key barrel. Scraped clean the inside contacts of the switch. You can burnish copper on brown paper bags. Then greased the contacts. I took no pictures of the key switch. To take it apart, near where a relief slot exists, pry into the 2 plastic catches to release the catch, this will release the switch assembly from the key, the 3rd catch just releases when the other 2 are free.
To disassemble multifunction switch, remove those 3 side screws, then slip it apart. This switch uses a set screw to secure it to the handle bar.
To remove the grip, I used a couple screw drivers and pulled it backwards, but have read you can shoot compressed air under the rubber handle to blow it off the handles.
The fail on the start red button slide was one of the interior copper connects had overheated deforming the plastic, so I had to enlarge the plastic space to allow the copper connect bar to slide smoothly in and out. It was stuck in the button.
This switch is a little trick to assemble,
important to install red button and the main white circuit component together into the black housing
it is important to have the red slider up all the way when installing light and reverse override buttons. This way you can lift the white circuit component up enough to fit them into place.
The spring for the start red button fits in last.
Left picture shows you assemble everything this way into one side of the cover, then slide the other black outer cover onto the pins.
I greased all the copper bars, springs and detent balls and switch elements for smooth operation anywhere it slides.
I used walmart's marine grease out of a cartridge. That grease repels water and is sticky enough to hold things in place as you put the switch back together.
Switch feels like new.
Took apart both switches and cleaned and greased and all are good again. This ATV had sat for about 5 years.
For starter switch used some 0w-40 oil poured into the backside of the key barrel. Scraped clean the inside contacts of the switch. You can burnish copper on brown paper bags. Then greased the contacts. I took no pictures of the key switch. To take it apart, near where a relief slot exists, pry into the 2 plastic catches to release the catch, this will release the switch assembly from the key, the 3rd catch just releases when the other 2 are free.
To disassemble multifunction switch, remove those 3 side screws, then slip it apart. This switch uses a set screw to secure it to the handle bar.
To remove the grip, I used a couple screw drivers and pulled it backwards, but have read you can shoot compressed air under the rubber handle to blow it off the handles.
The fail on the start red button slide was one of the interior copper connects had overheated deforming the plastic, so I had to enlarge the plastic space to allow the copper connect bar to slide smoothly in and out. It was stuck in the button.
This switch is a little trick to assemble,
important to install red button and the main white circuit component together into the black housing
it is important to have the red slider up all the way when installing light and reverse override buttons. This way you can lift the white circuit component up enough to fit them into place.
The spring for the start red button fits in last.
Left picture shows you assemble everything this way into one side of the cover, then slide the other black outer cover onto the pins.
I greased all the copper bars, springs and detent balls and switch elements for smooth operation anywhere it slides.
I used walmart's marine grease out of a cartridge. That grease repels water and is sticky enough to hold things in place as you put the switch back together.
Switch feels like new.