"the 'new' switch is soldered to the bottom of the 616 board..bypassing the onboard switch.. which the switch isnt there..its just the 'socket/connector' of where the onboard switch used to be.."
That may be your problem. If I am reading this right it sounds like you took the switch out.
Its been a while since I messed with my 616 and cant remember what the other pins do on the factory switch.
Now I cant really see how that can be the problem since you would think if you can bypass the switch with it off then the other pins aren't used but without being able to measure and actually see what the other pins do I am just guessing.
Still if you have the switch you might want to solder it back in and test again.
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