Ignition switch problem

[Leakin'_Lena]

I have a 2000 90 HP Evinrude, and the kill switch function of the ignition switch is driving me nuts. I'd bought an entirely new remote control, it came with an ignition switch. Got it all rigged, and ran into this problem: All by itself, the ignition key clicks from the 'run' position to 'off' with the safety lanyard is still in place. On this model, you can remove the safety lanyard (the key will snap to 'off') and then turn the key and start normally. That worked, but the detent that holds the key in the 'run' position is super weak and lets the key snap back to 'off' when I release the key after starting. If not then, it spontaneously does it at random intervals. It acts as if the safety lanyard had been pulled. (On this switch, the safety lanyard collar surrounds the keyhole. There is no separate kill switch, pulling the lanyard lets the ignition key turn to 'OFF'. So, I can't bypass it.)

I tried disassembling the switch to see if I could modify it for a more reliable detent, but ruined the switch and so I bought another - a genuine BRP. Same problem. To keep the engine running, I have to put a rod through the hole in the key so that the end of it is braced against something to prevent the key from turning left. Obviously, this costs me the safety of the safety lanyard, and it's inconvenient.

Has anyone else run into this problem? Any solution?