R/H Switchgear 80ST

[dr nosh]

I dismantled the R/H switchgear (Start, Run/Kill) to clean the switch contacts.

Now, I cannot get the dammed thing back together.

This is the Hella' Made in Germany', not the later lookalike 'Made in Japan version. (Looks identical from the outside, but is totally different inside).

Basically, the Run/Kill switch has a spring that fits into the red lever part, with a 3mm ball bearing that is sprung to run in 3 indents, giving the 3 switch positions Stop,Run,Stop.

I just cannot get the spring into position with the ball bearing. Lost the bearing twice on the floor, (spring 'twang' ) and twice found it with a magnet after a few minutes.

Has anybody else, taken this switch apart, and more importantly, how did you manage to re-assemble it. Is there a trick?

Lost a few hours riding yesterday due to this.

 

[dr nosh]

Cracked it, with a little patience

How did I do it?

Assemble the switch front and internal part to the handlebar mounting. This is to hold the inner part in the correct position, otherwise when you push the button/spring/ball in you also move the position of the inner part and, well you guessed that bit.

Use a tiny 'blob' of vaseline to hold the ball bearing to the spring whilst you offer up the button to the switch assembly.

This is the trick. Get a small piece of Blu-Tack, and roll out into a sausage. Position this around the ball and surround it. This will hold the ball and prevent it making a bid for freedom in the next step.

Use a small electrical terminal flat blade screwdriver and use the flat on the outside of the Blu-Tack to push on the ball, to compress the spring. Make sure that the Blu-Tack surrounds the ball.

At the same time gently ease the red switch lever in. You will feel the ball drop into the indentation before the switch lever is fully home. Carefully pull the Blu-Tack away and press the switch lever fully home.

Remove the switch assembly from the handlebar, keeping your thumb or finger on the switch lever.

Fit the C clip into position on the inside.

Re-assemble the switch.

Bish, Bash, Bosh.



TOP TIP. I mentioned patience in line one. This was an understatement. Don't take this switch apart unless you have bags and bags of patience. I lost count of the number of attempts to re-assemble until I came up with the Blu-Tack method.

Why did I take the switch apart you might ask.

Well it all started when a bod offered for free a R/H switch assembly with a nice red kill switch 'free'.
Nice, I thought, my kill switch lever is faded and has gone pink.

Took the 'new to me, switch apart, took my original switch apart (with the spring and ball 'pinging out').

Turned out the free switch was made in Japan, and my original switch was Hella, Made in Germany......both identical on the outside, but totally different on the inside.

So, in order to get the red kill switch that I desired, I painted it....cleaned, applied plastic primer, 2 x primer, 2 x Red, 2 x Clear Coat.

Err, that's when I found that it was not easy to re-assemble.

 

[cookie]

They are an utter bastard to get back together. I've done a couple and it nearly drove me round the bend.


Sent from my iPad using Tapatalk

 

[fayeslane]

Used a bit of Gummi Phledge on switchgear housing the other day, came up a treat.