Hello everyone, first time posting here.

I believe my ignition switch has gone bad on my 08 gs (checked battery and fuses) so I'm trying to replace it. I've taken off the triple with the ignition still attached by the two torx bolts. The problem is these bolts are COMPLETELY rounded off. Does anyone have any suggestions for removing these? Also, when I do put the new one on, what bolts should I use instead?

Thanks in advance!

Those bolts are made "rounded off" as an anti theft feature....which means you can't easily remove the ig switch.

I haven't done a GS500...but did remove the ig switch from my Yamaha...

Only way was grinding head on a Dremel tool...maybe a bit of drilling too...

Unless somebody has a better idea..

Cookie

Quote from: clayton25 on January 23, 2018, 03:42:04 PM
Hello everyone, first time posting here.

I believe my ignition switch has gone bad on my 08 gs (checked battery and fuses) so I'm trying to replace it. I've taken off the triple with the ignition still attached by the two torx bolts. The problem is these bolts are COMPLETELY rounded off. Does anyone have any suggestions for removing these? Also, when I do put the new one on, what bolts should I use instead?

Thanks in advance!

The same trick that finally worked in removing the carb float bowl screws -

secure the ignition core in a vise
get a sharp chisel and hit the screw heads horizontally / tangentially. try to dig the chisel in as firmly as you can with each strike, works like an air hammer

If your bike will always be parked safely inside somewhere, you can do without a key entirely, just like they do for dedicated track bikes.  I hid a high capacity switch for the electricals somewhere else on the frame.  Also got rid of the key core for the gas tank.  Very convenient not having to fuss around with keys!

If it is screwed and you are going to replace it and chuck it. cut a slot it the top and use a screw driver. You have to cut through the walls around the sides then into the head. That's how I got rid of mine. Then a little heat ( they are thread locked) or acetone.
Replace with button head allen screws.

Quote from: gregjet on January 25, 2018, 12:52:59 PM
If it is screwed and you are going to replace it and chuck it. cut a slot it the top and use a screw driver. You have to cut through the walls around the sides then into the head. That's how I got rid of mine. Then a little heat ( they are thread locked) or acetone.
Replace with button head allen screws.

+1 to this - they have some sort of Loctite holding them in - I used air duster to shrink the bolts.  Don't plan on re-using them - if someone can get to the wiring they can start the bike with a paperclip anyway.

You could also possibly drill out / use a screw removal tool to do the honors, but just getting a slot in there worked well for me.

OOPS I just remembered. The attachments on this MAY be wierd rounded NUTS. If you grind off the spread top to stud, with a dremel, and then use a small pin punch to undo them, it may be the way to go. Done so many projects on so many bikes, I can't be sure anymore. You will still have to remove the studs after and use allen bolts on the new one though.

Thanks for all the tips guys! I'm currently at college away from home, so whenever I get a chance I'll take it home and try the Dremel method and use a screwdriver. It's not always parked in a "safe" location (ie. on the street sometimes) so I don't think I'd feel right about doing without the key altogether.

Hopefully, after I replace the ignition switch the bike will be good to go; I really don't know what else the source of the problem would be.

I'll be sure to keep you guys posted on the results!

On my Yamaha Cafe racer...I didn't want that big ugly ignition switch module...so I removed it completely and replaced it with two waterproof toggle switches.  One switch shuts off the coil...just like the engine kill switch...and the other turns off the power to the system.

It would be possible to mount these switches in one or even two highly concealed places.  This might make your bike somewhat theft  proof.  I know some guys, even with the standard key type ignition switch who still have a concealed "kill" switch somewhere for further theft protection.

Where I live, stuff doesn't much get stolen...everybody has guns!


Cookie