Ignitionlight Switch Disassembled

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Servicing Ignition-Light Switch

(To identiy Items, Refer to Illus. 101)

See Item 24, under Illus. 102, 103 and 105 for information on switch operating positions.

1. After removing instrument panel cover, disconnecting wires and removing switch from panel, a faulty switch can be disassembled for inspection and repair as follows:

2. All switch part positions mentioned below apply with switch upsidedown. Switch must be in "OFF" position and unlocked.

3. Grasp end of center pin (6) with pliers and pull and move sideways to release contact bar (10) from retaining notch in center pin.

4. After contact bar has been released and removed, contact plate (9) with five terminals attached can be removed.

1946 and Earlier Model Switch: Note that contact plate is installed with the three terminals toward lock cover hinge.

1947 Model Switch: Note that contact plate is installed with the two terminals toward lock cover hinge.

5. Contact bar holder assembly (7) with reinforcing plate (8) and center pin (6) can now be removed from switch cover by sliding either one of the plate extensions out of retaining slot in switch housing (2) and then sliding opposite extension out of other slot.

6. Switch frame (4) and lock plate (5) can now be removed from switch cover. Note that narrow end of elongated hole in lock plate, and also lug on switch lock (3) which fits into hole in lock plate, are toward lock cover hinge.

7. Lock assembly can now be lifted out of switch cover. Avoid separating lock tumbler assembly from its housing.

8. Inspect switch parts, particularly contact bar and contact plate, for excessive wear of contact bar and contact buttons or otherwise faulty condition. Contact bar and contact buttons may be found worn to the point where they no longer make positive contact. Extreme wear of these parts may allow head of center pin to "short" against switch lock plate. Loosened terminals on stationery contact plate may also develop a "short."

9. Install new parts for any found worn or damaged. Scrape off any rust that may be found on head of center pin, apply a light coat of oil or grease to head of pin and lock plate, contact bar and contact buttons and proceed with reassembly, reversing order of disassembly.

10. Bear in mind that if lock tumbler assembly has been taken out of its housing, it must be reinstalled in correct position in relation to housing. Otherwise, it will be found after switch is completely reassembled, that switch can not be locked. To reassemble correctly, insert lock tumbler assembly into its housing with tumblers in any one of the four registers. While pressing tumbler assembly into its housing with finger tip, insert key and turn as far to right as possible. Remove key.


Horn operating (ground) button is on left handlebar. Tone adjusting screw is in back side of horn.

If a horn fails to operate and moving adjusting screw does not remedy the trouble, it will probably be necessary to disassemble horn and clean contact points.

When reassembling; tighten all bolts securely and then readjust tone by means of adjusting screw. Do not change position of adjusting screw in diaphragm.

Adjusting Headlamp

To get the greatest efficiency from headlamp and to meet the requirements of law, adjust as follows: Adjustment should be made in a darkened room or at night. Have motorcycle standing on a level surface about 25 feet away from, and headed toward a wall or screen upon which a horizontal line has been drawn at exactly the same height as lamp center. Motorcycle must be resting on both wheels and front wheel must be in straight-ahead alignment.

Turn light switch "ON" set headlamp dimming switch (on handlebar) in high beam position, and check light beam for height and direction. The top of main beam of light should register on wall or screen even with, but no higher than, the horizontal line mentioned. After loosening the clamp nut underneath lamp bracket, lamp can be tilted up or down to properly aim it in relation to horizontal line, and at the same time can be tinned right or left to direct beam of light straight ahead.

Lamp Bulbs

1946 and Earlier Models

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