Well...I finally after almost a year had a part go bad on my XB600. Yesterday when I rode home from work and went to turn the scooter back on to put it in my storage building...the key swtich wouldn't work. It turned but not with the usual kind of resistance and clicking. Nor would it stay in the "on" position.
Anyway, so obviously it had broken somehow so I took it out of the scooter and took it apart hoping maybe I could fix it. But that wasn't possible so I'll be on the phone today to order a new one from X-treme. It didn't look like anything really "broke" inside the switch...but more like something just wore out...probably the plastic piece that holds the contacts and turns when you turn the switch. Also, it could have been that the end cap where the outside wires are soldered to the switch...just released some from the switch. The only thing that appears to hold it in is some "crimping" of the metal around the end of the casing...and this metal is some kind of pot metal that turned out to be really brittle at this point. Anyway the thing I don't like about the wiring is that the wires connecting to the switch (red and black) go from the switch into some white insulation and are apparently soldered at a point right before they enter the insulation...and each solder area is covered with shrink tubing. Wonder why they didn't put a plug here? If the new switch comes with these wires...their entire length past the soldered points...I"m guessing to the controller...and I guess a plug there...well, you have to unwrap this bundle from all those other wire bundles (white insulation around each) and run it the entire length to replace it. Or, it may just be the switch with the wires pigtailed a few inches...and you have to unsolder the areas I've described and solder to the pigtails of the switch. A plug where they are soldered and covered with shrink tubing would have been nice! Anyway, guess I'll find out about this when I call X-treme to order the switch.
Thought I'd share a few pics here since I had the opportunity to take some when I took the switch out. Some of the pics are a bit fuzzy since I forgot to put the camera on "closeup" for some of them! Sorry! By the way, the switch is mounted on the scooter frame by two small bolts going in at the side of the switch housing/casing. They were easy to get out...and not as tight probably as they should be. It's a tight fit getting at them but not a big deal. Also that black finished piece that you see when you look at the keyswitch from the rider's view that has the "on, off, lock" indications justs turns and "unlocks" off the switch so you pull it towards you from the rider's side...and off. Best to do this after releasing the switch by taking out the two bolts...then you can pull it out some on the rider's side and easily turn and pull off that black plastic piece...then pull the switch back through and out of the front black panel.
Here's a pic of just the whole front opened up....notice what is apparently the dc-dc converter where those two silver screws are. That is the forward end and it is a silver case that is screwed and wire tied to the frame.
Here's two pics of the switch contacts...the ones on the end cap and the copper contact plate on the inside that makes contact with the end cap contacts. Notice as well (left pic) to the right the two wires, black and red, that are covered with shrink tubing. These are the ones coming from the end cap (switch).
Here's a pic of the inside of the housing/casing from the rear. And here's the stuff that goes in there...the contact plate and plastic spring loaded piece, a couple of ball bearings for it to roll on, etc.
Here's a pic of that front "round" fuse if you ever have to get to that to change it.
Well, hope I didn't provide alot of meaningless stuff here for xb600 owners. I just believe showing all this may help someone sometime! Oh, and last but not least, I'm wondering if the key is the same for all xb600s??? They wouldn't key them different would they!??? If so, then I wonder if I'm going to end up with a separate key for the on/off switch...from the battery box key and seat key...since these three keyswitches are all turned by the same key! Guess I'll know soon when I talk to X-treme.