It's extremely difficult to get my key to turn to the on or seat release position. It's like it's gummed up or something, or the key's teeth are incorrect or worn. I'll sit there for 5+ minutes sometimes trying to get it lined up so it can turn. Also, I had 2 copies of the key made, and neither work. I'm afraid at some point either the key will break in the ignition trying to turn it on. Has anyone else had this problem? Can anything be done short of buying a new ignition set with keys? It's only $150, but still, I would prefer to have the original working.

Maybe go to a locksmith with the bike and keys and talk to them. See if they have something that can be put in the ignition cylinder that can "read" the key cut? Wouldn't hurt to ask. They might have something that will work. Good luck.

before you go to a locksmith try this: put key in and get ready to turn it, put your knee on the nose of the seat and apply downward pressure, then turn the key. see if that helps you get it to unlatch.

I've got the seat unlock bit pretty well mastered, I can generally get it in under a minute. The problem now is the ignition, I fiddle and fiddle and the damned thing takes forever before it turns. It's not like it's the wrong position either, you can't move it up and down and have it click and turn for you. I think I'm going to put in some graphite and see if that doesn't help.

Other thought though. I like buttons. What if I wired 2 switches under the tank, one for ignition, one for key, and just put a big ass button there to start, so you reach under, flick the switch, press the button, and you're going. Could remove the starter button from the handle bar, one less wire and gizmo up there. I just got the damned thing and I'm already talking about tearing it apart and fiddling with it's insides...

is your first key the original? and do you have to try to line it up in to out? also try pushing the key down like you are going to go to lock then when it comes back up then try to turn to on, making sure not to push it down. if that still doesn't work try pulling the key out very small amounts at a time to see if the key was cut too deep on the shoulders

The only key that works is an origional. I have 3 cut keys that all look absolutely identical, but don't work for the ignition, only for the gas cap. I've tried pulling it out a bit, and a bit, and so on. It seems totally random. I'm fiddling with it more and more, maybe I'll learn it's trick.

if you bypass the key switch I think you would have to put a resister in the mix so the bike thinks there is the right ignition switch.

I figured that might be the case. I can measure the resistance between the poles and determine the resistance and put together a little pcb with the necessary parts and get that done no problem though. I didn't have to do it on my nighthawk, but I've had to do it on cars in the past.

if you have a dial caliper measure the original key from the shoulder cut to a specific point on the key, not the end. then check the copied keys, it's not uncommon for even a locksmith to cut them incorrectly

Try the graphite first it may just need a good lubing. If that doesn't do it the take the switch out and the key and go to a GOOD locksmith and have him fix it. He can put new pins in the tumbler and also cut you a NEW key that fit them at the same time. I have a special key that covers the whole switch and looks like a big bullet nut. I had it cut at a good locksmith for abut $3. They can rebuild the whole lock cheaper than you can buy one from a dealer. I have 4 keys total.