Ignition switch not functioning

Today I helped a friend swap some parts from one 1982 XJ 650 Maxim to an identical year and model bike with lower mileage. The bike runs great,but the key has no effect on the bike,whether it is switched on or swiched off. The bike can be started without the key,and all lights,indicators,and the horn function properly. It seems as if there is an unswitched supply of power coming from somewhere,but we couldn't figure it out.The only way to shut the headlight off is to pull the fuse,or disconnect the battery. I will probably be embarassed when I find out what is causing this,but all that I can think of is that it has a bad rectifier or something else that is allowing current to back flow. Being the electrical moron that I am,any insight regarding this matter will be greatly appreciated.

Also,are there any provisions to adjust the airbox? The boots don't quite cover the carb mouth areas,and I don't think that the boots shrink. I thought maybe the airbox could be distorted,but it appears to be fine.The boots are all mounted with the indexing tabs at the top,between the airbox tabs.I compared all the boots prior to installation,and they all appear to be the same length,but then my sight isn't as keen as used to be.There was no mention of any size differences in the Haynes manual

Thanks in advance;
Dan

 

Airbox boots do shrink, i had the same problem. Just bought new from dealers they were only about £3.50 each with the exchange rate thats about $7.

 

There is "Some" placement travel in the Airbox's fasteners.

You should loosen all the bolts holding the Airbox in the frame and "Wedge-it" forward and re-tighten the bolts.

If the Boots aren't covering the Carbs Intake Openings ... there is the chance that you have them:

Out of order. Mixed-up. The correct boot not in the right placement.

Mis-adjusted. There are little rubber tabs on the Boot. They need to be rotated to line-up within the locating pips on the airbox.

If there are no alignment tabs and pips ... rotate the Boot until you get its maxim coverage on the outside diameter of the Intake neck of the Carb.
Have an assistant hold the Boot forward while you tighten-up the Clamp.

be sure that the Boots are forward enough as they protrude from the airbox. There is a locating groove that saddles the Inside Diameter of the hole in the airbox where the Boot extends from.
Make sure that the Boot has that channel seated all-around.

 

try unpluging the plug for the switch

 

you cant get the boots out of order they are all the same. You just need to be aware they do shrink with age so if after trying all the adjustments if they still dont fit that could be the problem. Mine were about 6mm shorter and around 4-5mm smaller in diameter than the new ones.

 

Start by removing the headlight from the bucket and find the connector for the ignition switch. Check and see if its jumped out. If not, with the ignition disconnected, see if it will start. If not, then remove the ignition switch and take the lower half apart, it might be broke or not assembled right, staying in the on position whether the key is on or off.

If everything looks ok with the switch and it still starts with it disconnected, find those wires(3, I believe) where they come out of the wiring harness under the seat. See if you can find where it's shorted there.

 

Thanks,guys. Rick,the boot tabs are all installed within the indexing tabs of the airbox (facing the top of the airbox).The boots are properly seated,as well. I found the top mounting screw for the airbox,but was unable to find any others(too busy pulling my hair out).

Richard,I swapped out the switch for a known good unit,and it behaved the same,leading me to believe that the problem is elsewhere. I would be remiss if I didn't mention that the owner upgraded the fuse block to a blade type unit,and he found a green wire near the rear of the airbox that had some evidence that a rodent may have been snacking on it...He wrapped the insulation with tape,but I never gave a thought that it may have damage further down.

Finally,the owner use a jumper box to start the bike.Could this have damaged something? The switch functioned properly prior to the fuse block swap and the jump starting.

Tanks again,guys,I truly value your input!

Dan

 

I meant to say "thanks" guys. What is spell check,anyway?

 

Danno, the jumper box should be ok. My first guess would have been the ignition switch as well but you are right, it could be else-where.