Ignition switch broken

All these years I've never had the lock cylinder of a switch fail, then yesterday I ride the 77 KZ650 to work, shut off the key, it starts raining, then snowing and I'm looking for a "wonderful" ride home. I go out to start it and my key no longer turns the ignition, then out of the blue it turns real great over to "park" where it remains locked for eternity, I do the WD40 and nothing, so I disconnect the battery and begin my 4 mile trec through the snow/rain on foot Have I been lucky over the years or is this unusual? Those switches Z1 sells work like factory?

Ron, MAYBE, experianced the same w/my KZ550 A1 last summer. Emgo and Sudco offer replacement ign. switches. If application is exact, it may be a plug & go. In my case it was a trip to the schematic and dis-assemble new switch & re-configure. Key blank totaly different thus 2 keys. luck G. PS, after trying unsucsessfully to hot wire bike in parking lot, I now carry a blown up "dick & jane "copy of wireing schematic in tool pouch. Yarr

Ron I can cut you a key higher than spec to compensate for wear.
I suspect your key and the ignition itself are worn.
I'd cut it from the key code # if you know it, but as I said, higher than spec to compensate for the wear.
It may not work, and might need some filing if it's too tight.
If you could send me the ignition I'd be able to test and adjust the key right away.
That's if you can live without it for a week or so.

Let me know if you want to try something.

Thank's, I might take you up on that. Once the snow goes away I'm going to do some more investigating of the situation and go from there.

In May 2006, soon after getting my bike, I had to change my switch out. I went to a local Kawasaki dealer and ordered a new switch, cable and connector assembly for $22.99 CAD.

I see that Z1 is selling one for the 1977 KZ650-B1 for $15.40 USD plus shipping. From the picture, it looks like a SUDCO product to me.




I have noticed recently on eBay that custom cut keys can run about $20 USD. So I think I did OK.

I also see 2 key blanks bidding in the less than $10.00 USD range right now on eBay.

The switch assembly was plug and play compatible but the key was a different number. So, now I need two different keys to access my bike. I can live with that, no problem.

Best of success.

Thanks everyone. I went over to my parents house to search for my spare keys hoping they were still there and good news, they were and the key fixed the problem. Why in the world a key works 100% perfect for 13 yrs I've ridden this motorcycle, then one day doesn't is strange and it still works the seat just fine? Oh well, new key works is all that matters.

Ahh, so we've now discovered the weak point in the KZ650. You only get 200,000 miles because the key eventually wears out. :laugh:

If it happens again rather than being stranded, remove the headlight and find the plug from the switch and chafe the wires and twist together to hotwire the bike, then when you get home you can get it figured out. If you chafe the wires rather than cutting them you can repair them easier.

My 2 pennys worth