Ignition switch connector burnt - why?

[thor]

I have a K4S.

The green four pin connector that connects the ignition switch (under the snorkel opening) has one terminal that has got very hot at some point and has burnt and melted the plastic somewhat. This then results in a poor connection and for the bike to sometimes not turn on. The helpful AA man took it apart and polished it up, but he recommends I get a new ignition switch. Should be easy to get an fit I guess. However, if I do this, will it happen again? Is this a symptom of something more serious or was it just a dodgy connection? Do I need to replace the other corresponding part of the switch as well?

Thanks in advance to the mighty org!!!

John

[Sid Squid]

If the connector gets slack and doesn't grip correctly, then the current will cause an arc, (that is; little sparks), between the two parts of the connector - which is responsible for the heating and burning you have witnessed.

It quite likely that the connectors can be removed from the blocks, cleaned and reshaped and then all will be well. If you find that they're too damaged and not re-usable then they can be cut off and two new spades put in their place, even if they won't go inside the original block.

Replacing the ignition switch for a damaged connector would be excessive, and would mean that you'd have two keys too - inconvenient.

[thor]

It quite likely that the connectors can be removed from the blocks, cleaned and reshaped and then all will be well.

It seems that this is the most likely outcome. Thank you sir!