Glad to hear it is working for you- that is exactly why I make them!
It sounds like you have the dreaded stuck KiPass activation switch. As you have an early C-14, Kawasaki should replace the original spring with the newer, heavier spring used on later models. Between that and cleaning the switch and removing the burrs, it should all work find for quite a while after being serviced. This <should> be a free service, even though the bike is out of warranty as it was a manufacturing defect in the first place. No guarantee though- they may refuse it.
You can work on it yourself of course though it is kind of pesky in that security screws have to be drilled out from underneath the ign. switch housing, after it is off the bike. There are videos and overviews of how to do this out there in 'Net land though so you should be able to get a good idea what you need to do before starting.
Best of luck with this, it usually turns out fine once repaired / improved.
Brian
Just gotta say, this bypass switch came in handy on my 4 day trip! I've had it installed a few years ago after a stuck switch after a single incident. Fast forward to now...then on my recent trip this past weekend it got stuck all the time after the 1st day. Luckily I was able to reach down and pull the fuse EACH and EVERY TIME to get it started.
Buddies were looking at me the first time thinking I was hot starting it till I told them the issue. Wasted no time and able to start easily. Thanks again for the extreme life saver Brian!!
But now that I'm back, I need to diagnose why I can't push the switch to activate it. Any ideas on where to start? Think I'll remove the ignition assembly from what I recall on Fred's photos earlier and go from there...