You are 'discovering' seven year old information. It is great that you are investigating and everything but really, there is a lot known about this already.
The next step is to wonder what Kawasaki is going to do about this? Well, let's skip ahead to 2011 and see: ah yes, they replace the activation switch's return spring with a stronger one. By the way, this is undocumented by Kawasaki; there is no part number nor have they made this knowledge available but quite a few people have had this service performed.... at no charge because it is simply Kawasaki's way of trying to quietly and inexpensively solve a problem without alerting all C-14 owners to this problem. Now, how does the new spring work.... does it solve the problem? No, it merely reduces the instances of it happening. The cure would be to mechanically connect the key mechanism with the switch actuator so that the switch can be uncoupled directly, no matter how badly it sticks closed.
But again, all this information is out there and readily available. You are "discovering" some really old data and not quite making the best guesses as to how to solve this issue, all in my opinion of course.
Brian
Oh, and by the way: this is not quite correct for the multiple people that this switch has stranded. I suggest anyone interested do a Google search on the words "stuck" and "KiPass" for more (much more) data on this issue. When the switch sticks and cannot be released, it will strand the bike and rider.
Simple as that.
Brian
Yes I found plenty of info on the internet about tapping the top and side of the switch, plenty on people changing the springs for stronger ones, lots on faulty solenoid, there's even a video on Youtube by Brad Harrison posted in 2013 (
https://www.youtube.com/watch?v=otvC_AlqxUI) in which at the end he concludes there is something else at fault other than the solenoid, I think if he had have found this micro switch his video would have ended more positively.
I could find absolutely no info on this micro switch on the internet and wanted to get it out there, is`t that what these Forums are about sharing info. Yes the switch will most probably play up again in the future and be a bit of a nuisance, but now I know where to look and now as part of my routine maintenance make sure that I give the switch a squirt of WD40 or 3in1. Hopefully this will help someone else not getting stranded they will think to give the ignition switch at tap on the side and get the top hat out then they can get at the micro switch to make sure it free and get some WD on it and hopefully they`ll be on their way again. Or it saves them spending loads of pounds or dollar`s when there`s no need.
I take your point about plenty of people been left stranded I been one of them, but remembered reading about tapping the switch and waiting for the click to be able to turn top hat which got me home. Then the KIPASS started to play up more regularly so I decides to ring a main Kawasaki dealer here in the UK, they wanted the bike for 2 hours to investigate at £60 ($98) plus VAT (tax) per hour with no guarantee they could solve the problem and I might be looking at £650 ($1,000) plus VAT and labour for a new ignition unit. Kawasaki UK also thought it was a dodgy solenoid and no they would`t help as the bike is so far out of warranty. I could have spent hundreds of pounds or dollar`s on something that just needed a penny (cent) squirt of WD40 on a regular basis.
Its a simple fix that can save loads of frustration and money.
The pics show where this micro switch lives, you can just make it out under the metal tag. This can get stuck down and needs to be teased with a narrow screwdriver and a squirt of WD40 to free it. Make it part of your maintenance routine to check that its free, if you have your FOB with you as you to touch the micro switch you can make it out clicking away which shows its free.