Bad design of replacement part

[Auld]

1983 Venture XVZ12TK

My key failed to turn the ignition main switch, and I could feel that the pins in there were totally trashed. Nothing was going to fix this but a replacement of the whole ignition.

The old part number was 26H-82501-00-00.

The new part number is 26H-82501-01-00.

It finally arrived and what a surprise. The new part is designed in such a way that it cannot be installed without some major mechanical work on it.

The two bolts that hold this main switch in place are in a recessed cavity, like a little volcano with a hole at the bottom for the bolt. (See photo Original Part.) I had to use two long extenders on my 3/8" drive to get to it, because it was so far up in the front end, but get to it I did and removed these bolts.

However, when it came to installing the new switch, this recessed cavity is much narrower. Sure, the bolt will fit in there, but there is no way to also get in there a #10 socket or an open-end or box-end wrench, or even the points of needle nose pliers. None. Nada. Nix.

 

I spent three hours cutting down three sides of the volcano walls on each side. (See results of this not-very-pretty work Replacement Part.) I used my drill with regular drill bits and a special side-cutting bit. I used my Dremel with cutoff wheels, grinding wheels, and even two dental bits that I obtained from my dentist some years ago. I even used a saber saw.

 

Someone, somewhere didn't think about having to install this when they designed the replacement part. If I knew who to forward this information to a Yamaha HQ, I would certainly do so. Anyone know how to do this? Really, if this new ignition switch is common to a lot of years of Ventures, the pain will be spread a long way. I wonder if they use this part in new bikes, and if so, how to they turn the bolts?

 

Comments welcome, especially if you can tell me how to get this info to Yamaha HQ.

[twigg]

Wasn't it possible to change the bolts for cap-head bolts?

[Condor]

Wasn't it possible to change the bolts for cap-head bolts?

 

When I replace an ignition switch I always replace the hex heads with cap screws. Way easier to get them up though all that wiring on the end of a hex socket...

[MiCarl]

When they superseded the switch assembly they probably also changed to a socket head screw.

 

**EDIT**

 

Just checked. They changed the mounting bolt too. These kinds of things can be quite frustrating.

[Auld]

Well, cap screws is certainly the right answer. Wish I had posted this before doing all that cutting. However, in the end I got the switch installed, and it all works now. Now I wonder, how was I to know that? The switch didn't come with mounting hardware, which is listed separately. At any rate, if I had given it a bit more thought before breaking out the grinding tools, I would have saved myself a lot of time.