How to replace the ignition switch

How to replace the ignition switch

Introduction

This article describes how to replace the ignition switch on a Ninja 250. Typically, this will need to be done because some dunderhead had to discover for himself that you really can't steal this bike by jamming a screwdriver in the lock.

The procedure is fairly straightforward. You'll remove the top triple tree, drill off the security bolts, bolt on the new switch, and put it all back together. This even works with the fork lock engaged. If you have all the tools together, and a reasonable working environment, it shouldn't take more than about 2 hours. Add time as necessary for getting parts or tools.

Tools Required

In order to replace the ignition switch, you will need the following tools:

• Large crescent wrench (10-12")
• Metric hex key set
• #2 Phillips screwdriver
• Electric hand drill
• 1/4" to 3/8" drill bit
• Screw extractor
• Vice grip style pliers
• 10mm socket
• Socket wrench
• Pliers
• Clean rags

You will also need the following supplies:

• 2x M6x16 bolts (see below)
• Red thread locking compound (high strength)
• Blue thread locking compound (low strength)