HDS 2135 ignition switch plug melted down

Ace1959 · Dec 3, 2018

I have a HDS 2135 that the plug to the ignition switch melted totally. Looks like one of the other wires came in contact with the battery feed. I guess a wires or wires came loose (?) allowing them to touch(?).

I no longer know which wires go to any of the spade connectors on the back of the ignition switch so going by the wiring schematic color codes I wired in a standard simple ignition switch in the original's place. No place for the ground wire (I've never seen a ground wire on an ignition switch (for a safety interlock?)) so I left it and the headlight wires off (headlights long gone). It turns over great but I'm not getting any spark.

I don't know if the original switch is still good or not. I've tried to figure out the terminals by checking continuity but I think the switch may be bad. I have ordered a replacement switch and a stub harness with a new ignition switch plug.

I'm assuming that the stub harness and new switch will solve my issues.

Does anyone have the pin outs for the ignition switch plug? The old one was melted and I didn't note the wire locations before cutting it away.

Does the ground wire not being attached affect any safety interlock circuits and therefore prevent running?

Do you think replacing the ignition switch plug/harness and switch will allow it to start and run?

A lot of questions but the schematics I've seen does't show how the wires attach to the rear of the ignition switch....

Ace1959 · Dec 3, 2018

Your small picture above should definitely help. Just need to verify the legend.
B=battery
A=alternator
S=starter
G=ground
L=lights
M=magneto?

Ace1959 · Dec 4, 2018

Ace1959 said:
Your small picture above should definitely help. Just need to verify the legend.
B=battery
A=alternator
S=starter
G=ground
L=lights
M=magneto?

K7LN, thanks for the pinout info. I reattached the original wires using the small photos above and it runs great. The ignition switch requires some finagling to make the start contacts but after that it runs and everything works. I have a replacement ignition switch on order as well as a stub harness for the switch. This should be my permanent solution.

Ace1959 · Dec 11, 2018

Ace1959 said:
K7LN, thanks for the pinout info. I reattached the original wires using the small photos above and it runs great. The ignition switch requires some finagling to make the start contacts but after that it runs and everything works. I have a replacement ignition switch on order as well as a stub harness for the switch. This should be my permanent solution.

Installed the replacement ignition switch and the stub harness for the switch wires and all works as it should.

K7LN, thanks again.