How to Install a New Ignition Switch on a Mini Motorcycle

Written by william machin
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How to Install a New Ignition Switch on a Mini Motorcycle
Install a new three-position ignition switch in your mini motorcycle. (Jupiterimages/Creatas/Getty Images)

Aside from changing a spark plug or tail light lamp, installing a new ignition switch on your mini motorcycle or pocket bike is one of the least complicated replacements. The ignition switch is an integrated unit that is held in place with a trim ring. A moulded electrical connector eliminates the need for a wiring schematic or any confusion surrounding wire colour codes. Depending on the style of switch, tightening the trim ring requires an inexpensive tool or a some grip on your part. Park the mini motorcycle on its kickstand or centre stand to install a new ignition switch.

Skill level:
Moderate

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Things you need

  • Ignition switch that matches the motorcycle
  • Trim ring tool

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Instructions

  1. 1

    Attempt to loosen the trim ring on the existing switch by pressing down as you turn the ring counterclockwise. Use a trim ring tool if the ring does not loosen by hand. Remove the trim ring.

  2. 2

    Reach under the instrument cluster and follow the path of the ignition switch wires to locate the snap-in connector. Press the tabs on each side of the larger stationary connector, and pull the switch wiring female end out of the connector.

  3. 3

    Lift the ignition switch out of its mount and feed the female wire connector through the underside of the mount to remove the old switch.

  4. 4

    Insert the female connector of the new ignition switch through the mount in the instrument cluster. Align the tab on the body of the ignition switch with the offset in the mount and push the switch into place.

  5. 5

    Reach under the instrument cluster. Align the raised ridge on the female connector with the groove in the male connector. Push the female connector into the male connector, making sure it snaps firmly into place.

  6. 6

    Thread the new trim ring clockwise onto the new ignition switch and tighten it by hand. If necessary, tighten the trim ring with the trim ring tool.

Tips and warnings

  • Protect the new trim ring with several wraps of masking tape when tightening the ring with adjustable pliers.

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