What's the best way to remove the Ignition

[KTM AL]

Hi Chaps
I have a replacement ignition to fit. I did try a search or 2 without any luck so here is my question.
What is the best way to remove the two security bolts holding on the ignition? I thought of removing the top yoke and use an Irwin bolt remover on a rattle gun . But I thought I'd ask first, as someone must have done it on here and might have a better cunning plan. Cheers

 

[bimota]

here you are

Main ignition switch overhaul

Riding home from work today I lost the use of my indicators, park and tail lights.... the culprit. That’s the bottom of the ignition switch with the cover off. I thought I would share that you don’t need to rush out and buy a new immobiliser/main switch assembly if this happens to your bike...

yamahasupertenere.com

rob

 

[KTM AL]

Thank you for the link, I am taking the entire ignition unit off, the shear headed bolts look to be M8 as that is the diameter of the holes in the replacement unit. Drilling will be the second plan, I might add a bit of heat too, as there might be thread lock in there. Third plan would be to mill the heads off.

 

[Saint rob]

I’ve removed quite a few steering locks over the years and all I’ve ever used is a sharp centre punch and hammer. I tend to tap the centre punch into the edge of the security bolt before tapping it anti clockwise, once it’s loosened it’ll spin out easily (providing there isn’t any Loctite) Always worked for me

 

[KTM AL]

I’ve removed quite a few steering locks over the years and all I’ve ever used is a sharp centre punch and hammer. I tend to tap the centre punch into the edge of the security bolt before tapping it anti clockwise, once it’s loosened it’ll spin out easily (providing there isn’t any Loctite) Always worked for me

Thank you for that Rob Prehaps I was over tthinking it. I will try that first, I can't do it yet as I am unable to remove the tank and didnt want to damage it, I'm waiting for a key to be made for the seat lock.Cheers

 

[KTM AL]

I have just managed to change the ignition, getting the security bolts undone was a bit a mission. Thanks to Rob, I used a punch and hammer to get them out ,they did have a fair bit of thread lock on them. When I removed the old ignition from the bike I tied on another cable for each so they would be correctly routed when I reinstalled the replacement ignition cables , taped them on and pulled then through.
I'll put the battery in tomorrow and see if it goes.

 

[KTM AL]

The removed ignition bolts

 

[BrushSTormn]

I have just managed to change the ignition, getting the security bolts undone was a bit a mission. Thanks to Rob, I used a punch and hammer to get them out ,they did have a fair bit of thread lock on them. When I removed the old ignition from the bike I tied on another cable for each so they would be correctly routed when I reinstalled the replacement ignition cables , taped them on and pulled then through.
I'll put the battery in tomorrow and see if it goes.

I'm just starting this project, with any kind of luck my new ignition lock set will be in the mail tomorrow. I have many questions, but I believe most of them will answer themselves as I go along. One thing I'd like to know ahead of time is what size bolts you used for a replacement? Do you know size, length, & thread pitch? Thank you for your time!

 

[KTM AL]

Hi
I'm not sure about the exact size , but I think the bolts I used are Domed headed Hex M8 1.25 thread and around 25mm long . I did get some M3 x 8mm hex head screws for the immobilizer. Good luck with the project.

 

[BrushSTormn]

Hi
I'm not sure about the exact size , but I think the bolts I used are Domed headed Hex M8 1.25 thread and around 25mm long . I did get some M3 x 8mm hex head screws for the immobilizer. Good luck with the project.

Thanks for your response. I will pick up a couple of round head socket screws to replace those with. Fortunately (or not?) the rain has set in so I've got until spring to get this project completed.

 

[stutrump]

I just cut a slot in mine with a dremel and then got a flat head screwdriver on them. Came out fine. Good luck!