Thanks for all the info. When I got my 650 out this spring the ignition kept cutting out while riding it for the first time and I had to keep wiggling the key to get the bike to turn back on so I could restart and continue on my way. The bike has been sitting since then due to a crazy amount of work and a new baby. This weekend I finally got to break down the headlight to get to the ignition switch and thanks to everyone's posts on this and other "Ignition Switch" topics I was pretty quickly tell that the problem was the corroded switch contacts. The main hot contact was a bit pitted due to resistance buildup and the plastic was just starting to discolor but had not really melted yet so it was still quite usable. I cleaned everything up with some 600 grit paper, swapped the sprung contacts to opposite sides of the switch and reassembled. After putting everything back in the bike it turned right on with no key wiggling and wiggling would also not get the ignition to lose contact so I am back in business! Now if only I could bring a six month old and a workstation with me I'd be able to ride it :-)
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