PITA ignition switch.

[Ericthejet]

More advice needed for the old bike.
I have a replacement ignition switch that I need to install.

I have access to the mystery fasteners that hold it in place.
Not a hex as no room is available in the barrel the fasteners are placed in.
Not any sort of Torx, male or female.

The center is a different color, almost like dull brass and they seem to almost look like a hex but with small lines arranged in a pattern.
A friend was with me and we grabbed a mirror and had a good look.
He and I have concluded that they must be a rivet as the center "nib" as described above is a different color from the washer that almost matches the barrel size.

Any thoughts? Perhaps a rivet?
Will I need to drill or dremel these out?

Thanks.

[KB]

You will need dynamite for such a job

[Degsy]

They are security torx. probably size 45.

Does it look like this?



If it does, I have it. mail me your address and i'll send it to you but make sure you send it back.

degs

[butcher bergs]

+2 on the security Torx screws.

I bought a set of bits from Napa Auto Parts I believe.

[Ericthejet]

Degsy,

Nope, not at all like that. I wish they were a Torx at this point.
If the switch is the original one could they be a rivet from the factory?
I'll try and get a picture if it comes to that point.
In this image it looks very much like the item at the top right of the page.
http://www.sz-wholesale.com/uploadFi...mall_41606.jpg

[Ericthejet]

In this image, top right is almost the same except the center portion is not as high.

http://www.boltmotorcyclehardware.com/images/rivets.gif

[Degsy]

In this image, top right is almost the same except the center portion is not as high.

http://www.boltmotorcyclehardware.com/images/rivets.gif

Those are plastic bodywork clips. When you insert them, the top pushes flush. To remove them, press in on the center piece and they loosen up and fall out. I doubt that's what are on there as they are a more modern fastener and only plastic.

They might be covers for the real fastener underneath. Did you try pushing on the center piece to see if anything happens?

Try to get a digital pic. can you remove the whole top triple with ignition?

[Ericthejet]

Well, what I have sure isn't plastic but the look is the same basic idea.
I have not tried pushing on the center piece yet.
If by the end of the day these are still a mystery I will make use of my camera and post up a picture.

Thanks again for the help.

[noudidnt]

They might be the same bolts I have on my 10r.... I had to take off the upper triple, and use a hacksaw to cut a groove in the head, and back them out with a screwdriver. Literally the only way to remove them. Then just replace with a regular torx bolt.

[Ericthejet]

They might be the same bolts I have on my 10r.... I had to take off the upper triple, and use a hacksaw to cut a groove in the head, and back them out with a screwdriver. Literally the only way to remove them. Then just replace with a regular torx bolt.

Yup, that is the tactic to remove these as they are indeed break off bolts.
The ignition switch is not threaded so once the heads are drilled off you can let the switch fall away.

Thanks.

[Ericthejet]

Good news.
The upper triple tree came off with not too much fuss. First time for me.
I then set about to remove the "special" fasteners that hold the ignition switch in place.
As some have speculated, and it was confirmed by a friend in Florida these are break off fasteners from the factory. After a few passes with increasing sized drill bits they released their 25 year hold on the switch.
Once off the triple tree bracket I was looking at two 1/4 in height threaded leftovers. As luck would have it I didn't need to reach for another tool to back them out as they turned quite easily with my fingers. I was a bit shocked to tell you the truth.
Tomorrow I will be the first one in to the local hardware store to pick up some metric fasteners to complete the task.
I'm glad this didn't turn into a giant cluster-f_ck.
Thanks again to all who offer guidance. NESR is a handy bookmark on my Mac and I think I owe some here a coffee.

Now, about the leaking oil cooler line.

[SSearchVT]

You'll find the same type of bolts on auto ignition switches - the shadetree mechanic repair is to do just what you're planning. If you're concerned about someone trying to take the bolts out to steal the bike - use hex head bolts and crazy glue a BB into the recess in the head.

[Ericthejet]

I have decided to use a large phillips head fastener.
I'm not too worried about the theft issue and if I ever need to remove the switch in the future I have an offset tool for getting to those hard to reach areas.
Thanks for the tip. Free coffee for you as well!