Lowlife, I haven't had that happen with my 94 900, however I have had it happen on several different bikes in the past. Typically 1 of two things happens, either the handlebars aren't turned all the way to the stop (keeping too much pressure on the locking mechanism) and the lock won't disengage (in that case, just crank the handlebars all the way to the stop, then try again)
or
There is some crap built up in the switch. Spray it with a little wd-40. I've done this with several different bikes, without it ever causing a problem. I'll bet that you have a little bit of corosion built up on the locking mechanism that isn't allowing the key to work properly unless you've applied PERFECT pressure on the key (and probably holding your mouth just right, while hopping on 1 leg, singing yankee doodle dandee). Just spray the wd-40 straight into the lock, then put the key in and turn it a few times and see if that doesn't help.
Hope that helps.
or
There is some crap built up in the switch. Spray it with a little wd-40. I've done this with several different bikes, without it ever causing a problem. I'll bet that you have a little bit of corosion built up on the locking mechanism that isn't allowing the key to work properly unless you've applied PERFECT pressure on the key (and probably holding your mouth just right, while hopping on 1 leg, singing yankee doodle dandee). Just spray the wd-40 straight into the lock, then put the key in and turn it a few times and see if that doesn't help.
Hope that helps.