Btown Bagger

I have taken off fairing cap and key switch to install and wire driving lights. I cannot get switch and lock back together, it has whipped my butt. What's the secret to this?

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B-1B_Guy

Kicked my butt when I installed new bars.....download the service manual or try this....not sure what step you're on but this is directly from the '09 Service Manual that I downloaded from this site.

7. FLHX, FLHT/C/U:
a. Install fairing cap. See 2.38 FAIRING CAP: FLHX,
FLHT/C/U.
b. Using oblong holes in fairing brackets and a long
shank ball end socket (Snap-onŽ FABL6E), install
four socket head screws to fasten radio (storage box
on FLHT) to left and right radio support brackets.
Alternately tighten screws to 35-45 in-lbs (4.0-5.1
Nm).
c. Install outer fairing. See 2.37 UPPER FAIRING AND
WINDSHIELD: FLHX, FLHT/C/U.
8. FLTR: Install instrument nacelle. See 2.43 INSTRUMENT
NACELLE: FLTR.
9. Install switch position plate fitting tabs in slots of fairing
cap (FLHX, FLHT/C/U) or instrument nacelle (FLTR). Plate
snaps in place when properly installed. Exercise care to
avoid breaking tabs. Replace plate if tabs are damaged.
10. See Figure 7-55. Install spacer over threaded post of
ignition switch housing until it contacts switch position
plate. Orient spacer so that the widest side is forward and
the inside tabs fit in slots of post.
11. Slide collar over threaded post until it contacts spacer.
Orient collar so that the outside tab is forward and the
inside tabs fit in slots of post.
12. Thread nut onto post with the lipped side down and the
smaller OD topside. Turn the front forks to the right fork
stop, and using a 7/8 inch Open End Crow Foot on flats,
tighten nut to 125-150 in-lbs (14.1-16.9 Nm).
13. Install spring into bore at underside of knob.
14. With the knob pointing toward the FORK LOCK position,
insert shaft into threaded post. Holding the knob down,
turn key clockwise to UNLOCK. An audible "click" should
be heard when knob and switch are properly engaged.
Release knob and then rotate through all four switch positions
to verify proper operation. If knob will not install
properly, proceed as follows:
a. See Figure 7-50.Verify that button at bottom of knob
is pressed and key is turned 60 degrees beyond the
UNLOCK position.
b. Repeat this step.
c. If knob does not install properly, move to previous
step.
15. Knob was removed in ACCESS or switch may have been
moved out of the FORK LOCK position. Proceed as follows:
a. See Figure 7-52. Insert alignment tool until bottom of
handle contacts top of threaded post, and holding
front forks at the left fork stop, rotate handle of tool in
a counter-clockwise direction until fork locks.
b. Remove tool and repeat previous step.
c. If knob does not install properly, move to next step.
16. Detent and switch position lugs are misaligned. This can
occur when the alignment tool (or ignition switch knob) is
HOME
7-48 2009 Touring Service: Electrical
rotated before it is properly bottomed in the ignition switch
housing. Proceed as follows:
a. Reinstall knob inserting shaft into threaded post and
gently rotate knob until it drops into the partially
installed position. Take note of the position of the
knob, that is, whether it is pointing toward the rear,
or to ACCESS, IGNITION or OFF.
b. See Figure 7-56. Remove knob and insert alignment
tool so that the bottom of the handle is approximately
0.500-0.0750 in. (12.7-19.1 mm) from the top of the
threaded post, and then hold.
c. Rotate alignment tool in a counter-clockwise direction
the number of positions needed to get to FORK
LOCK. For example, if the knob dropped into the
partially installed position at IGNITION in step 16(a),
rotate the alignment tool two positions in a counterclockwise
direction. Or if the knob was pointing toward
the rear when it dropped, rotate the alignment tool
four positions in a counterclockwise direction or one
position in a clockwise direction. Repeat step 14.

Btown Bagger

B1-B Guy I don't know how to thank you enough. What a ordeal thanks again.