Hello! My 2005 650 did something really weird yesterday. I rode it to work, rode it mid day, all fine. When I left in the evening I turned the key on, then back off because I forgot something.....and the headlights and dash didn't turn off! Cycled the ignition switch several times, same result, started engine, same result - turning the ignition switch off didn't kill the engine, although the kill switch did, but the lights still stayed on. The key action felt normal. OK, I figured I'd ride it home and then disconnect the battery. But when I got home the ignition switch worked normally! And today, so far so good. So somehow, my ignition switch turned on and was not responsive to turning the key back off, but then riding time and maybe vibration fixed it, at least for now.
This is not the first time I've had weird behavior from the ignition switch, see the thread below if you're interested. After that I followed the instructions also linked below to take the switch apart. I didn't really find any anomalies, everything looked pretty normal in there. No cracked solder joints, loose conductive objects rolling around inside the switch, that kind of thing. I cleaned everything, greased it and put it back together. This is the first time it's acted up since.
So what the heck? Maybe the tab that clocks the key portion to the switch electrical portion is wearing out and coming undone occasionally? But again, it didn't look worn when I worked on it. Maybe it's time to bite the bullet and buy a new ignition switch. Anybody seen this behavior? Thanks!
My previous thread from 2016:
Reference thread for fixing ignition switch: