I had this problem too and I found if you turn the handlebars to the right and back again it turns the key easily. I know it's weird but it worked. Ken

Where did you get that key Curt? I've seen pics of some and they look real cool

First, I would try to clean all the build up crap that can get into the tumbler barrell. The canned air used for computer key boards work great for this but be careful not to much as it will turn to moisture. Then a small amount of grafite. If that doesn't free it up, isolate the issue. Disconnect the seat release cable and make sure it is free. Check the steering lock pin and make sure it isn't sticking. Car ignition switches go bad but normally that is due to heavy key rings hanging on there or people parking against the curb putting pressure on it, niether the case here. If all else fails and if nothing else is sticking put the WD-40 to it. The next step is get it to the bench, I'll still bet it isn't the lock assembly other than a good cleaning as it works fine in the gas cap along with the copies. Good luck I do like your idea of the modification as well.

Les

Hey nasomi....I have a buddy that did your switch idea on his Electra Glide. He mounted 2 toggle switches up on his trees. He kept the starter button in place on the control housing though. He then totally removed the key assembly. He kept the fork lock on so he can secure it as it's now startable without a key.

Good luck on cleaning yours out. Sounds like you got some gunk down inside the shaft.

Regards....greeny

Thanks for all the input. I'll hook up the compressor and blow air with that, tends to work well and not have moisture. Graphite it up and see what happens. If nothing works I'll see about a locksmith in my area, hopefully he'll be able to fix it if i can't.

I think it's gunk in the lock. I like the push button mod myself