started to install a few things on the front end today.
Wanted to test the audio before putting it all back together BUT I can't get the key switch back in.
 I have stuffed around for hours and no joy.
I can get the bars locked to the left by putting a screw driver down inside (NOTE a helper thought it was a good idea to try and turn it every which way)
With bars locked left I can get the key lock in but cannot get it to connect and stay down. It's almost like it isn't going down far enough for the tag to slide in to hold it down in place.
 
Any ideas?
All the info I have found is mostly about how to get it apart Not back together.
 
cheers
Max
 

Ozymax
I went through this shit 7 years ago mate but it is easy to fix you need to put the forks on full lock to the left to engage the steering lock. Then you insert a flat blade screw driver all the way in on the bottom lock to engage it. When the steering lock is engaged you can turn the top rotor to get the ignition post back in to release the steering lock and get ignition. If that makes sense your half way there.
I did post this fix 7 year back but its probably been lost over time. 

Send me your mobil number via PM and I can help you through the fix if you still have problems.

cheers mate I will give it ago and be in touch if I am still stuck, I think I have already tried every possible way but maybe the screw driver was to big and not getting down to the bottom section.
You post may still be here but the search function isn't that user friendly
thanks for the help

From memory it was a quarter inch flat driver but only one off my 1/4s drivers done the job. I tried every posable location with the tumblers but it wasn't untill I engaded the steering lock that I got anywhere. It took me 2 days of cursing the fucking bike and reading the manuals and internet to get my head around the fix. Its one of those fucking jobs that takes hours and hours then it just falls in place.

 

just had another go but no luck, get some 1/4" tube tomorrow and flatten it out. It seems to be the bottom key way not lining up so the shaft doesn't drop down far enough. would have thought turning it through 360 would resolve it but no joy. If I can engage both key ways I think it will come together.
What a fucking ridiculous set up for an ignition switch, but having seen the top triple tree this morning nothing would surprise me from HD any more

The bottom one is no better jump on your bike and give the bars a good shake and feel the steering flex. I sent you a PM hope it will help

I don't need to feel it, just looking at it is enough. It actually handles OK for the size of the thing, can only imagine how much better they would be with a descent set of trees and forks.
I am already into this thing to far to go down that road at the present unfortunately, maybe one day

I might have to read my bible again to jar the memory into gear but I'm sure the driver size with clicking the tumblers over was the key once the lock was engaged.

I know the feeling after spending 7 years on frame and engine mods. LOL

yea only had the thing a month and got more on the bench than I ever did with any other bike.
But hopefully this one's a keeper and should be all done in a month.
Getting the right gear is taking some doing to my surprise.
Been fucked around by experts before but some of these yank suppliers take the cake. some are brilliant also.

Mine was self induced. I had to use the correct Harley tool to get it all lined up. Lucky I could get a lone of one. Have had it apart a few times since and now that I know whats going on it's no issue at all.