Warning: To prevent the risk of short circuits, disconnect the battery negative (-) lead before making any ignition (main) switch checks.
Check
1. On XL models and XRV750-L to N (1990 to 1992) models, remove the fairing (see Chapter 8). On XRV750-P models onward (1993-on), remove the air filter housing (see Chapter 4). Trace the wiring from the ignition switch and disconnect it at the connector.
2. Using an ohmmeter or a continuity tester, check the continuity of the connector terminal pairs (see the Wiring Diagrams at the end of this Chapter). Continuity should exist between the terminals connected by a solid line on the diagram when the switch is in the indicated position.
3. If the switch fails any of the tests, replace it with a new one.
Removal
Note: Some switches may be secured by shear-head bolts - these bolts can only be used once. Obtain new bolts before starting.
4. On XL models and XRV750-L to N (1990 to 1992) models, remove the fairing (see Chapter 8). On XRV750-P models onward (1993-on), remove the air filter housing (see Chapter 4). Trace the wiring from the ignition switch and disconnect it at the connector. Work back along the harness, freeing it from any clips and ties, noting its correct routing.
5. On XL650V models fitted with the HISS immobiliser system, undo the screws securing the receiver around the ignition switch and remove it. noting how it fits.
6. On models with shear-head bolts, the heads of the bolts must be drifted round using a suitable punch or drift, or drilled or ground off. before the switch can be removed, and so the top yoke must be removed as described below. On models with standard bolts, you should be able to get at them with the switch in situ, in which case unscrew the bolts and remove the switch. If not you will have to remove the top yoke as described below.
7. Displace the handlebars from the top yoke (see Chapter 6). There is no need to remove assemblies from the handlebars.
8. Slacken the fork clamp bolts in the top yoke (see illustration) Unscrew the steering stem nut and remove the washer (see illustration). Lift the top yoke up off the steering stem and position it clear, using a rag to protect the tank or other components if it is only being displaced (see illustration).
![](https://motoinstruction.ru/img/honda/19/126083.jpg)
19.8a. Slacken the clamp bolts (arrowed)...
![](https://motoinstruction.ru/img/honda/19/126084.jpg)
19.8b ...then unscrew the nut...
![](https://motoinstruction.ru/img/honda/19/126085.jpg)
19.8c ...and lift off the top yoke
9. Unscrew the bolts (see Step 6 if required) and withdraw the switch from the top yoke (see illustration).
![](https://motoinstruction.ru/img/honda/19/126086.jpg)
19.9. Ignition switch bolts (arrowed)
10. If required, undo the screws securing the contact plate on the bottom of the switch and separate it from the barrel.
11. Replace whichever part of the switch is faulty, or the whole switch if necessary. If required assemble the barrel and contact plate and secure them with the screws.
Installation
12. Installation is the reverse of removal. If you are using shear-head bolts, tighten them until the heads shear off. Otherwise tighten the bolts securely. Make sure the wiring connectors are securely connected and correctly routed, lighten the steering stem nut, fork clamp bolts and handlebar bolts to the torque settings specified at the beginning of Chapter 6.