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Ignition switch replacement

steve mahoney

Member
Member
Since a new part is not available to replace the ignition switch on my '87. Is there a go-to new part that is compatible ?  ( Plugs in and can mount properly )
J-Box and everything else is sound,and I have a used part available.But since this is my forever bike, I'd like to go with new.
 
The switch (and key) p/n 27005-5064 seems to be as you say, discontinued.. but may be found on ebay as a "new, old stock" item... you need to do the legwork..

https://www.bikebandit.com/oem-parts/detail/kawasaki/27005-5064/b795869


The switch assembly for 1994 thru 2006, which is p/n 27005-5101, is still available, about $136 new, from Kaw and Ron Ayers.
I'm almost positive its "plug and play", but the pre 94 part had one "dangling additional wire", that plugged into a single wire connector under the dash.. id have to check what it was for, but if you have a FSM you could effectively see the differences in the pinouts of that switch if any are different, and in reality they are all the same in function..

Mind you, its necessary to drill out the anti theft pins on the screw heads to remove the switch, basically drilling the head off, and pulling the switch, then removing the screw stubs with pliers. New screws should be purchased to accommodate.

Edit to add...
After looking quickly at both schematics, it appears they are the same,.the dangly wire should be on the switch from all years, and this should plug and play fine.
 
An ignition switch from an 80-83 KZ 550c was an exact match for my 86 C-10... And cheap. $60 after shipping
 
‘87 C10, intermittent contact for the rear running lights. How do I get in here, and what can I do to make a positive contact ? As it stands now I have to jiggle the key to make contact to get the rear running lights to illuminate. I do have a ‘99 C10 available for parts if I need to swap out the ignition switch, steering stem, and wiring harness. It’s pissing me off, and nagging at me when I’m underway wondering if I’ve got tail lights. The previous owner was in there to upgrade the springs, she’s solid and doesn’t dive.
 

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I don't recall anyone talking about how to take that switch apart to fix it. There may have been awhile back, but usually if it is the problem it is replaced.

Usually, it turns out to be intermittent contacts inside the Jbox (cracked solder connections/relays). I would look at that first and make sure it is ok.
 
Try smacking the j box when it's acting up. We don't hear much about bad ignition switches. We hear a lot about bad j boxes. Even if it's not the problem, it would be good to have yours reworked. There is also a thread by m in SC that shows how to create a setup that uses std auto relays that can replaced as easily as a fuse. HTH
 
I took the switch apart on my son's Vulcan 750. I broke the housing to take it apart, not easy. Several small pieces inside. The contacts were intermittent due to corrosion from sitting outside near the gulf coast. I was able to clean it and get it back together. Later that year he had intermittent lights and we found the relay /fuse box overheated and damaged. That might have been the problem all along. Look into the relay box first.

I have seen full lock sets for sale on e-bay. I have thought of getting one because one of my bike use 2 different keys. 1 for the ignition and tank another for the seat and fairing pockets.
 
As I recall the rivet attachment was different on 86-93 vs. 94-06?

For the 94-06 Ignition Switch, Partzilla says it fits the following models: (might help in a search for a used part).

Kawasaki Motorcycle 1996 GPZ 1100 - ZX1100-E2 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2002 Concours - ZG1000-A17 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1999 Concours - ZG1000-A14 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2005 Concours - ZG1000-A20 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1996 Ninja ZX-11 - ZX1100-D4 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1996 Ninja 500 - EX500-D3 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1994 Concours - ZG1000-A9 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1994 Ninja ZX-11 - ZX1100-D2 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2006 Concours - ZG1000A6F Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2009 Ninja 500R - EX500D9F Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2004 Concours - ZG1000-A19 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1994 Ninja 500 - EX500-D1 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1995 Ninja ZX-11 - ZX1100-D3 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2001 Concours - ZG1000-A16 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1999 Ninja ZX-11 - ZX1100-D7 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1995 Ninja 500 - EX500-D2 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1995 Concours - ZG1000-A10 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1995 GPZ 1100 - ZX1100-E1 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1999 Ninja 500R - EX500-D6 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1998 Ninja 500R - EX500-D5 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1998 Ninja ZX-11 - ZX1100-D6 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2007 Ninja 500R - EX500D7F Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2001 Ninja ZX-11 - ZX1100-D9 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2001 Ninja 500R - EX500-D8 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2004 Ninja 500R - EX500-D11 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2002 Ninja 500R - EX500-D9 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2005 Ninja 500R - EX500-D12 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2008 Ninja 500R - EX500D8F Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1997 Ninja 500R - EX500-D4 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1996 GPZ 1100 ABS - ZX1100-F1 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2000 Concours - ZG1000-A15 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2000 Ninja ZX-11 - ZX1100-D8 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2000 Ninja 500R - EX500-D7 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1993 Ninja ZX-11 - ZX1100-D1 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2006 Ninja 500R - EX500D6F Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2003 Ninja 500R - EX500-D10 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 2003 Concours - ZG1000-A18 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1997 Ninja ZX-11 - ZX1100-D5 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1997 GPZ 1100 - ZX1100-E3 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1997 Concours - ZG1000-A12 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1998 Concours - ZG1000-A13 Ignition Switch/Locks/Reflectors

Kawasaki Motorcycle 1996 Concours (Canada Only) - ZG1000-A11 Ignition Switch/Locks/Reflectors
 
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