Boxerworks.com

so my bike wouldn't start today. Same thing I had two weeks ago. Press the starter and nothing.

So in testing the neutral switch, starter relay, etc. I pulled apart the ON/OFF, Starter, turn signal switch array.

So I figured I could remove the circlip on the OFF/ON/OFF switch and pop off the level. Well it doesn't work that way....and then a small bearing that fits into the notches to get 3 positions...goes flying...on my rough driveway that looks like a whole bunch of little bearings.
And the spring that presses up against the bearing got bent....
searched for the bearing for an hour, used a magnet, used my air compressor to see if I could blow stuff around and may see it moving...no luck.

and then I figure out that you can't get the #$%#!in! turn signal switch cap off so you can't fully disassemble the thing to fix the spring and find a replacement bearing.

Then I look up the prices to replace the unit...$175 WTF!!!!! It's .30 worth of plastic and $2 of cable.

So my options seem to be
A: pay through the nose to replace it.
B: look for a used one and sit on my thumbs until one comes up.
C: cut out the ON/OFF switch and it's innards and wire up a different switch.


I will probably go option C because I have a few days off next week and might do a couple day trip.
Other options? (kick myself in the butt has been done enough today).

You aren't the first, and won't be the last. Bummer.

When opening the switches.
Rule #1. Open it within a large plastic bag. Something will go flying.
Rule #2. Do not disobey rule #1.

Maybe if someone has one open, the size of the ball bearing, and the spring could be described? If you're lucky, the spring might be something used in a pen or some such thing.

Failing all of the above, if you want to go for option C, I have a nice on/off/kill switch off an old XL250 (its a seperate handlebar switch) you can have for the $6.60 500g postage envelope.
Craig

BoxerTwin wrote: So my options seem to be
A: pay through the nose to replace it.
B: look for a used one and sit on my thumbs until one comes up.
C: cut out the ON/OFF switch and it's innards and wire up a different switch.

Or you could use the ignition key to shut off your engine while waiting for a reasonably priced stock kill switch to show up. With your "s" bike, access to the key is good. You will, of course want to find neutral before shutting off your engine, unless you're very agile and can reach over with your right hand to turn off the key while your left hand is still pulling on the clutch lever. (Or you could simply let out the clutch with the bike in gear, and your foot on the brake, and let the clutch out to kill the engine. The two or three seconds that your engine is not running with the ignition key still "on" won't hurt anything. I've used the kill-the-bike-then-switch-off-the-ignition approach too.)

I've never encountered a time, other than on my old Husky 360MX, when a kill switch was needed for an emergency shut down. I do use my kill switches, but only because it's more handy than not, and in order to keep the switch contacts 'burnished'.



Ken

Ken in Oklahoma wrote:

BoxerTwin wrote: So my options seem to be
A: pay through the nose to replace it.
B: look for a used one and sit on my thumbs until one comes up.
C: cut out the ON/OFF switch and it's innards and wire up a different switch.

Or you could use the ignition key to shut off your engine while waiting for a reasonably priced stock kill switch to show up. With your "s" bike, access to the key is good. You will, of course want to find neutral before shutting off your engine, unless you're very agile and can reach over with your right hand to turn off the key while your left hand is still pulling on the clutch lever. (Or you could simply let out the clutch with the bike in gear, and your foot on the brake, and let the clutch out to kill the engine. The two or three seconds that your engine is not running with the ignition key still "on" won't hurt anything. I've used the kill-the-bike-then-switch-off-the-ignition approach too.)

I've never encountered a time, other than on my old Husky 360MX, when a kill switch was needed for an emergency shut down. I do use my kill switches, but only because it's more handy than not, and in order to keep the switch contacts 'burnished'.
Ken

I was considering this. The switch still works, it just doesn't lock into position. It can drift up or down. I was thinking of pinning it and doing the key thing but it seemed sort of not right. I guess it's a fine thing to do. I've never needed an emergency kill switch...but once I got rid of it, I know I'd need it.

You mean you guys use your kill switches? I never do, maybe I should get in the habbit. It gets imbarrasing when you can't start your bike outside the Airhead meeting and then you suddenly realize that someone switched your kill switch to off.

mattcfish wrote: you suddenly realize that someone switched your kill switch to off.

I did that to a friend on the warmup lap before a race.
I thought it was funny.
As payback he blew my doors off in the race.