Flat Key Ignition Switch Kit

J004562013-11-01

GENERAL

Kit Number

71441-94

Models

1975 and later XL models

1982-1994 FXR models

1973-1985 FX models (except FXST and FXWG)

Kit Contents

See Figure 2 and Table 1.

Installation - 1994 FXR and FXLR Models

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)

WARNING

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

Remove seat and electrical panel cover. Disconnect battery cables (negative cable first.) Remove ignition module mounting plate.
Unscrew ignition/ light lock ring and push switch back through hole.
Disconnect switch wires at circuit breaker. Note where wires are connected. Remove old switch.
See Figure 1. Install new switch red wire on silver post of main circuit breaker.
Install new switch red/ black wire on copper post of ignition circuit breaker.
Install new switch red/ gray wire on copper post of accessory circuit breaker.
Use cable strap as required to secure wires.
The word "TOP" is marked on top of switch body (beneath plastic sheathing) to allow for proper positioning of switch. Install switch, align with correct switch label positions, install nut, and tighten nut (maintaining switch position.)
Install ignition module mounting plate and electrical panel cover.
See Table 1. Connect battery cables (positive cables first.) Test switch operation. Install seat.

WARNING

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

WARNING

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

1	Main circuit breaker
2	Accessory circuit breaker
3	Red/gray wire
4	Lighting circuit breaker
5	Ignition circuit breaker
6	Red/black wire
7	Red wire

Figure 1. Circuit Breakers and Connections - 1994 FXR/FXLR

Installation - All Models (Except 1994 FXR and FXLR Models)

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)

WARNING

1.	Remove seat and disconnect battery cables (negative cable first.) Save all seat hardware.
2.	See the Service Manual. Remove nut and switch.
3.	Perform the following model specific wiring procedure (See Installing Wire Splice section of this Instruction Sheet.) See Figure 2 , Figure 4 and Figure 5. Switch must be spliced into existing wiring harness using three blue (small) butt splice connectors. Use heat- shrink tubing around all three butt splice connectors for cosmetic purposes. Use cable strap as required to secure switch wires. See Figure 3. Switch must be spliced into existing wiring harness using two yellow (large) butt splice connectors. Use heat-shrink tubing around both butt splice connectors for cosmetic purposes. Use cable strap as required to secure switch wires.
4.	See Figure 6. The word "TOP" is marked on top of switch body (beneath plastic sheathing) to allow for proper positioning of switch. Install switch, align with correct switch label positions, install nut, and tighten nut (maintaining switch position).
5.	See Table 1. Connect battery cables (positive cable first). Test switch for proper operation. Install seat.

Table 1. Key Positions for Various Models

Key Positions Using This Kit Note: Key position functions may differ from those of original switch.	Position #1 (Full left)	Position #2 (Center)	Position #3 (Full right)
All 1994 and Later Models (Except FXRP)	OFF - All electricals. Key removable.	Hazard warning flasher, brake light, and horn may be activated. Instrument lights are ON.	Ignition and lights ON.
All 1993 and earlier Civilian Models and 1984 - 1990 FXRP Models (Except 1986 - 1992 FXRT/ FXRD w/ radio And Except 1991 - 1994 FXRP)	OFF - All electricals. Key removable.	OFF - All electricals. Key removable.	Ignition and lights ON.
1986 - 1992 FXRT, FXRD Models with radio; 1991 - 1994 FXRP Models.	OFF - All electricals. Key removable.	Accessories ON. Key removable.	Ignition, lights, and accessories ON.

WARNING

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

1	Switch
2	Blue butt splice connectors
3	Original wiring harness

Figure 2. 1994 and Later XL Models

1	Switch
2	Yellow butt splice connectors
3	Original wiring harness

Figure 3. 1993 and Earlier Civilian Models and 1984 (Except 1986 - 1992 FXRT/FXRD with Radio and Except 1991 - 1994 FXRP)

1	Switch
2	Blue butt splice connectors
3	Original wiring harness

Figure 4. 1986 - 1992 FXRT/FXRD Models with Radio

1	Switch
2	Blue butt splice connectors
3	Original wiring harness

Figure 5. 1991 - 1994 FXRP Models

1	Decal
2	Bracket
3	Nut
4	Flat key
5	Ignition switch

Figure 6. Flat Key Ignition Switch Installed - Typical

Installing Wire Splice

1.	See Figure 2 , Figure 3 , Figure 4 and Figure 5. Using a wire cutter, cut off wires of new ignition switch approximately 3 in. (76.2 mm) from switch body. Cut off ring terminals from ends of original wiring harness wires, leaving sufficient harness length to splice wiring and properly mount new switch.
2.	See Figure 7. Strip 3/8 in. (9.5 mm) of insulation off both wires to be spliced. Insert shrink tubing over original harness wires; slide tubing along harness and away from splicing work to be performed. Insert the wires from new ignition switch and wires from original harness in opposite ends of the appropriate splice connector.
3.	Match the color of the butt connector with the color of the crimp cavity of the crimping tool. Crimp wires into the connector using HD-38125-8 crimping tool. NOTE Avoid directing heat toward any fuel system component. Extreme heat can cause fuel ignition/explosion resulting in death or serious injury. Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed. Always keep hands away from tool tip area and heat shrink attachment.
	WARNING Do not use heating devices on or near fuel system. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00376a) WARNING Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a) WARNING Be sure to follow manufacturer's instructions when using the Robinair Heat Gun or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00379a) WARNING Be sure to follow manufacturer's instructions when using propane torches. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00465c)
4.	Using the UltraTorch UT-100 (HD-39969), Robinair Heat Gun (HD-25070) with Heatshrink Attachment (HD- 41183) or other suitable radiant heating device, heat the crimped splice to encapsulate the butt splice connection. Apply heat from the center of the crimp out to each end until the meltable sealant exudes out of both ends of the connector. Slide shrink tubing into position covering bundle of butt connectors. Apply heat in same manner as with butt connectors to seal tubing over connectors.

1	Stripped wire ends inserted in connector
2	Wire ends crimped in connector
3	Connector after heat has been applied

Figure 7. Installing Sealed Butt Connectors

Figure 8. Service Parts

Table 2. Service Parts

Item	Description (Quantity)	Part Number
1	Ring Terminal (3)	9862
2	Sleeve, ignition switch	71418-94
3	Butt Splice Connector, blue (3)	70586-93
4	Butt Splice Connector, yellow (3)	70587-93
5	Shrink tubing, dual wall	72268-94
6*	Ignition Switch Assembly	Not Sold Separately
7	Ignition switch mounting nut	71552-94
8	Keys, ignition switch (2)	71451-94 (Specify Key Code)
9	Cable Strap	10039