I did use the correct tamperproof Torx bit. However because of the Loctite they just stripped the head (they are pretty delicate screw heads). I was reluctant to cut a slot because of possible damage to the plastic. I think I'll try it however. If it fails I'll just modify the wiring on the new switch by splicing the Black/White wire to the Black wire as I said before. The end result is the same as the original switch ie the switch when ON connects Red (battery +ve) to Black (ignition) to Black/White (fan supply).

 

No need to possibly risk damaging your new ignition switch only to find they may not be mechanically compatible. Since this is an electrical issue, let's apply an electrical solution. I did similar fix with incompatible ign-switch for my VFR along with someone else recently on 600RR.

Yes, you can bridge blk wire to blk/wht on switch side of harness. Due high-current needs, use linesman/western union knot with lots of solder and heat-shrink electrical tape for maximum strength, conductivity and corrosion resistance. It's done this way in pro-motorsports (F1/MotoGP), military and aerospace applications for performance, reliability and durability.



This was only way to resolve burnt connectors on VFRs where Honda used 1/4" spade connectors with 24a rating in 30-40a circuits.





No more burning!

 

Thanks for your comments. Youre right to point out that the two switches might not be exactly mechanically compatible. As you say it might be best to use an electrical solution to an electrical problem. I'll modify the switch loom by splicing the Black/White to the Black. I'll use a heat shrink compression connector and also cover it with a heat shrink tube.
As a general comment I think the Chinese make a pretty good job of copying the mechanical part of these Honda motorcycle ignition switches. However I think they have trouble coping with large number of different wiring arrangements devised by Honda 2 wire/3 wire/4 wire/pink wire/Zener diode/HISS non-HISS/different types of connector etc etc
The new switch is fitted and works well including HISS and Meta alarm. Just got to get the fan sorted by doing the wiring mod to the loom. It's not a problem because I can do it on the bike.
Thanks everyone !!