Ignition switch problems

[Brian 93957]

Ive recently had the odd occasion where my Pi wont turn over on the key  Ive checked the starter is ok and the wiring is secure and fault free. ive noticed that wiggling the key in the lock whil turning the key usualy cures the problem so i assume the switch behind the lock must be the cause. Does anyone know if it is possible to dismantle the lock assembly to clean the contacts in the lock and if so how is it done?

[Deleted User]

My 2500 tc is doing it aswell! the only time Ive had one to bits was when I lost my keys! that resulted in wrecking the barrel to get it out the way and operating the switch with a screw driver! anybody got a spare with key!?

[Brian 93957]

The pi is behaving at the moment so ill leave the switch alone until it becomes a pain
but if any one does know how to correct it without breaking it please let me know.

[shenderson]

The switch can be removed from the barrel assembly - there are a couple of tiny self-tapping screws holding it in place.  However the switch is a sealed unit so you can't dismantle it, but it might be possible to squirt some electrical switch cleaner inside.

Sometimes the problem lies inside the lock assembly.  There is an adaptor inside that is fitted between the lock barrel and the ignition switch.  This adaptor transfers the rotation of the barrel to the ignition switch as you twist the key.  Being cast from soft alloy, the adaptor eventually wears, resulting in lost motion between the barrel and the switch, which prevents the starter contacts being operated.

Unless you have access to a workshop capable of making a replacement adaptor (and nylon would be a good material to use as it's resistant to wear) or someone with such capabilities, the only solution is a replacement lock assembly.

Note: it is possible to remove the lock assembly without destroying it.  Simply use a junior hacksaw to cut a screwdriver slot in the heads of the "secure" headless fixing screws.  You will inevitably also cut slots into the surrounding raised flange of alloy but that is hardly a problem.  You can then and unscrew the screws - they are not fitted very tightly.