Updated, Thinking of installing a engine Start Button, (Tumbler?)

JMinNJ

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So I’ve replace the ignition switch on my Bavaria twice. A new one when I bought the car 3 years ago then another when it started having no start issues again a couple of months ago. Always started with a button between battery and starter. I installed a new one that is staring to have issues. I have to turn the key several times to engage the starter. Install a starter button between the starter and the battery and it engages so it’s not a starter problem. Is there something I’m missing?
I ready to run a start button into the car.

John
 

dang

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Did you happen to take one of the "bad" ignition switches apart to see if there was anything obvious? Burn marks, melted plastic... It might give you a clue to the problem if it's not the switch itself.
 

JMinNJ

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Did you happen to take one of the "bad" ignition switches apart to see if there was anything obvious? Burn marks, melted plastic... It might give you a clue to the problem if it's not the switch itself.
Switch I removed looks fine on the outside. No melting or looseness. I haven’t taken it apart.
The first one I removed three years ago literally fell apart when removed.
 

jmackro

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A relay would be an alternative that would be a less visible. A simple SPST relay, mounted near the starter, could be powered by the heavy-gauge wire going to the starter. Even a compromised ignition switch would probably supply the few milliamps necessary to trip a relay.
 

jmackro

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I have to turn the key several times to engage the starter. Install a starter button between the starter and the battery and it engages so it’s not a starter problem. Is there something I’m missing?
Two ideas:

Might the female connector at the starter solenoid be flakey? Unplugging that to clip on an remote starter switch gets around this problem, leading you to believe that the ignition switch is the issue.

Might your starter solenoid be drawing excessive current (due to an internal short, or ???) causing the "start" contacts in your ignition switches to fail prematurely?

...or maybe you just have bad luck with ignition switches and the third time will be the charm.
 

dang

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When I have situations like this I plug the switch into the harness with out the tumbler, like in your photo, then use the key or a screwdriver to turn it. You have a much better feel for whether it's contacts that way. After that, I jump the wires on the back to see if that works. If it does it's the contacts in the switch.
 

JMinNJ

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When I have situations like this I plug the switch into the harness with out the tumbler, like in your photo, then use the key or a screwdriver to turn it. You have a much better feel for whether it's contacts that way. After that, I jump the wires on the back to see if that works. If it does it's the contacts in the switch.
Well I pulled the ignition switch from the key/tumbler of the steering column. I actuated the switch with a screw driver and it works fine. Actuated the starter as it should. So it seems to be the key/tumbler is not turning the switch far enough to engage the starter. Key rotates fine and i can feel the little spring at the end that should actuate the starter but no go. The tumbler needs to rotate another fraction of an inch. I made sure that the switch is in the tumbler securely and not moving when the key is turned.

I suspect I need a new tumbler and key?

Seems like it could be a bear to replace.
 

duct-tape

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The slot that the tumbler fits into to turn the switch, your may just have a little slop in it from wear. you may want to try a shim, like this?
1563659755445.png
 
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