Thursday, May 20, 2010

Rebuilding Lucas handlebar switch


#@%!, still waiting on a few key parts to really get this bike back together. In the meantime, I have been working on small projects (though there are no unimportant ones). The Control Switch for the left side had no bullet connectors and the button springs were shot. I ordered new bullets and springs and hit the casing on the polishing wheel. Not bad:





7 comments:

  1. Where did you get the parts for the handlebar switch? What did you use to hold the switch together (I assume you drilled out the rivets?).

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  2. I bought the plastic switches and springs as a kit off of eBay for $40 (ouch). There were no rivets holding the electric switch board in place, just two small phillips head screws. The switches themselves I picked up at Oley Swap Meet (PA) for $5 each! Compare that to current eBay prices!!

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  3. Hi Smythe
    I have the same switches for my project but the left hand side is not a two way switch, it only stays in the up position and the bottom position springs back to middle, would you know what I need to do to make it stay in the bottom position, Is it the plastic bit itself??
    cheers mate
    Mark

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  4. The left switch only goes from the middle to the up position. There is no down position on that side, just low and high beam. If the switch is not moving easily or staying in the up position than check to see that the spring and ball bearing are seated properly under the electronic board which is held in place by two screws. Just be carefule you don't lose those or the other springs for the buttons (two each per button). It's tricky to get the ball bearing to stay in place on the spring, so I used some greese to hold it in place while reattaching the circuit board. The switch should movevsmoothly otherwise the spring and ball aren't seated properly. Patience is key.

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  5. Smythe,

    thanks a lot,
    so which bit runs the indicator??

    is it on the RH side??

    the operation is the same as the LH side except reversed,

    Mark

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  6. sorry, missed this question, the right switch is the indicator. the switches are not the same. Theres a left and a right.

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  7. Nice Job on the switch, I need to do a set for a Norton, I enjoyed this post and looking through your Blog. FYI, those are Posi Screw that hold the base on the housing not rivets. Posi heads look like philips but they are shaped differently so more often than not a philips will strip them out.
    Gary

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