Ok, sometimes I turn on the key, and nothing happens. I’ve tried wiggling the key, and that doesn’t appear to be it, which is good because I just bought this ignition switch. I’ve narrowed the problem down to the top left corner of the fuseblock. This is where the main red/black hot wires go in and out of the fuseblock. If I just barely touch/wiggle/press in the red/black plugs all will work again. This could be kinda annoying if they wiggle loose while motoring down the highway at night so I pulled the fuseblock apart…
Back of the fuse block, the plug missing in the second pic is a green plug going up to the speedo cluster that I had off the bike at that point.
One plug refused to come out, I figured out why as soon as I pulled the back off of the fuse block. The red/black wire coming off the old ignition switch was burned by a loose connection and had done some damage to the plastic fuseblock. The plug still stuck in there is the main red/black line going into the wiring harness. I tried prying with a couple small screwdrivers and a sharp knife and couldn’t get the plug out. The plastic of the plug has fused with the plastic fuseblock. For what it’s worth, I was able to pull the metal bar that the plug contacts with and clean it.
Closeup of the damage. I cleaned up the contact as well as I could, they appear to be tight enough. I wasn’t able to wiggle the metal bar around too much. I repacked the fuseblock with plenty of grease to try and keep any further damage from occurring. Eventually I need to replace this fuseblock. I also replaced the fuses with all new ones. The old ones were still ok as far as their fusible links, but the plastic housings were dry rotted and crumbled when I pulled them out.