Topic: Kill Switch help...Any Ideas?

[GroovieGhoulie]

I think the kill switch is bad on my new Hodaka since it just started not giving me spark no matter if the switch is in "Off" or "Run".  I troubleshot it and found out that if I kick it over and, while the engine is spinning, move the switch from "Off" to "Run", there will be one or two sparks while the switch is somewhere between "Off" and "Run", but once in "Run", no spark.  This leads me to believe something is wrong with the kill switch.
 
Is this as simple as replacing the kill switch?  If so, I'll order a new one tomorrow.  I took the entire switch apart and cleaned everything with contact cleaner and a points file.  No dice. 
 
For those that don't know, there is no key to a Hodaka, the Kill Switch IS the ignition, (flip to "Run", kick it and go), so it gets a lot of use.

Any ideas about trying different rebuilding techniques or is the switch likely cratered or do I just need a new one?  The top of the red switch is all ground down with holes in it as if someone dumped it off road and it slid on some rocks, so it's not NEW by any means.

[csendker]

Can you jump it out?  Two alligator clips and a hunk of wire would certainly tell you if it's the switch or something more sinister.  Then you would know whether or not to order a new one.  Of course, if it's as beat as you indicated, maybe you want a new one anyway, but at least you'd know if it was the problem or not.

[GroovieGhoulie]

Can you jump it out?  Two alligator clips and a hunk of wire would certainly tell you if it's the switch or something more sinister.  Then you would know whether or not to order a new one.  Of course, if it's as beat as you indicated, maybe you want a new one anyway, but at least you'd know if it was the problem or not.

Good Idea.  I'll go buy some clips tomorrow and try that.  That WOULD be a rather foolproof way to figure it out.  I'm 90% sure it's the switch though, since the rest of the bike is so damn simple.  Magneto fired, no battery, etc.

[Jonesy]

If it's magneto fired then the switch may short out the magneto to stop the engine. In that case also try for spark with the switch wires disconnected and not making ground anywhere on the bike.

[GroovieGhoulie]

If it's magneto fired then the switch may short out the magneto to stop the engine. In that case also try for spark with the switch wires disconnected and not making ground anywhere on the bike.

Well I just unhooked the ground for the switch under the tank and there was big, blue, powerful spark!  And lots of it!!!  And there was much rejoicing.

I found out I have the wrong kill switch on my bike.  The Chrome Tank Dirt Squirts had a black button you press and hold to kill the engine, and they were WAY more reliable than the regular Off-Run-Off switch.
 
I'll be ordering a proper black button first thing.

[GroovieGhoulie]

Well I jumped the gun a little.  Bike ran fine all day today, but after stopping a few minutes ago, I went to re-start and nothing.  Tried to push-start when my leg got tired.  Nothing.
 
Pushed it about 1/2 mile home and pulled the plug.  No spark. The switch is totally out of the circuit, so I'm flummoxed.

Checked all the wires and none were worn through and grounding.  Both the blue and black coming from the magneto seem to be alright.  Could it be the coil?  The spark got intermittent for a bit, then nothing, again.

I pulled the sidecase over the magneto and there was some water in there, maybe from when I washed it.  I poured it out, figuring it wasn't helping anything.
 
From what I could see the points needed to be cleaned, gapped and dressed, possibly replaced.  They were filthy. Could it be the points?

I might try spraying some cleaner in there now without pulling the flywheel, and see what happens. 

Also the mag cover didn't have a gasket, but someone had used "HondaBond" or a similar gasket paste to seal it.  I have some of the Honda stuff for a future case-splitting project.  Would it work to seal this?