| Handlebar Switches |
| Written by Jonas Zahn | |
| Tuesday, 01 June 1999 | |
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After pricing a new set of switches for the starter, signal, and kill switches at $110, I took the liberty of consulting the Airheads list and fixing the starter switch myself. The following is a compilation of list advice and my findings.
Dissassembly: 1. Disconnect negative battery lead as with all electrical work. 2. Remove the switch plate from the handle grip by removing a single screw near the bottom and center of the switch plate. HINT: Use a clear plastic bag (Zip Loc Freezer bag works perfect) to cover the switch plate and your hands as you work to catch any loose parts. These parts are small and will be difficult to find if you lose them. 3. Remove the kill switch by pulling the c-clip from the back side of the switch. Carefully pull the switch out of the housing. A spring and a #3 ball bearing should pop out with the switch. 4. Remove the signal switch by removing (with a needle-nose pliers) the pin that the signal switch pivots on. Carefully remove the switch and catch another spring, #3 ball bearing, and a small copper conductor that inserts into the side of the signal switch. 5. Now you can remove the black switch plate cover from the white switch housing. 6. Check all connectors and leads to be sure they are clean and placed properly. 7. Use an electrical cleaner to clean the electrical leads and contact surfaces. NOTE: My starter switch problem was due to one of the starter switch leads dislodged from its place. Assembly: 1. Put the switch cover plate back into place. 2. Assemble the signal switch by inserting the copper conductor, spring and ball bearing. HINT: Use small amount of super glue to hold the ball bearing in place on the end of the spring. HINT: If you lose the ball bearing, use a #3 ball bearing to replace it and not #4. Too large a ball bearing will ruin the plastic bumps and you will no longer have distinct switch positions. I used the plastic head of a pin from my wifes sewing kit as a substite before I knew I could purchase #3 ball bearings. HINT: If you lose the spring, you can take apart a lighter and use the spring that holds the flint by trimming it to the appropriate size. 3. Get help (smaller hands work better at this one) to push the ball bearing and spring into the spring hole as you slip the switch back into place. Try using a very small screwdriver to compress the ball and spring. 4. Insert the pin that the signal switch pivots on. 5. Follow a similar procedure to insert the kill switch. 6. Put the switch plate back onto your handle grip and test after re-connecting the negative battery lead. Follow similar procedures for horn and headlight switches on the left-hand side. |
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| Last Updated ( Tuesday, 19 July 2005 ) |