Aux Light - Switch Broken - (Problem Solved)

After 6 hours yesterday working on my bike trying to figure out why the aux light on my xj750 seca stopped working i finally figured it out. I used a test light to test everything imaginable and when it all came down to it it was becuase the aux light switch is malfunctioning.

sometimes the switch would work (usually only when i opened the controls up) and mostly it didnt work. i even Removed the little switch via the internal screw in the controls, and blew compressed air in it. i even scracted it with a dentist pick. all in all it still doesnt work.

so heres my question. what should i do? i really really dont want to buy a set of controls just to get this 19mm x 7mm switch. i even looked through a catalog of i my local electronic parts retailer to see if they had a switch of that size but no luck.

is there any more i can do to try and clean this little switch. is it possible to somehow obtain this little switch? (the salvage yard said no obviouslly, they want to sell the whole controls) should i rig up my own switch. any of the vets here actually taken the switch out and opened it up to clean it thoroughly?

what would you do if you were me. (and you wanted to keep and use the aux light)

 

Re: Aux Light - Switch Broken

I guess it would all come down to personal preference. Do you want the original switch on it, or do you not mind putting a different kind on there? I would probably just find a small switch and be done with it.

 

Re: Aux Light - Switch Broken

IkeO, I took the switch out, bent the prongs securing the housing to the switch board (careful when you do this, there are little pieces in there) out just enough to sqeek the board out, and then cleaned everything. I also regreased the switch with dielectric grease to prevent future corrosion issues. Squeezed everything back together and gently bend the switch housing prongs back into place.
Now this works with a good switch. If your wiper is worn out or the rocker is broken, spring for the used cluster, the switch is not available as a separate unit. Worst case, you could buy one of those auxillary handle bar switches and wire the light through the new switch.
Best of luck!

 

Re: Aux Light - Switch Broken

thanks guys. robert im gonna try that. (opening up the switch,cleaning it, and greasing it) ill let you know if it works.

 

allright! got it fixed. thanks robert. you definatly gave me the confidence to just open the switch up. just to help others ill post what i did with pics.

1) opened up throttle handle bar controls and removed the screw holding the aux light switch in.


2) cut the wires connected to the switch and took the switch out. there is a small pin that holds the switch lever. in order to get that pin out to open up the switch i had to smash the end of the pin down hard with some pliers to make it more round so it could slide out. when opened there are VERY tiny pieces inside. if you let these pieces fall out while you are opening up i would bet you $100 you'd never find them again. thats how small they are. there is a small contact tab, a small spring and a small ball bearing. i cleaned all of these parts so that they became shiny again. then reassembled the switch back together. and re-smashed the pin end flat so it would stay in place.


3)Finally i put the switch back into the bike. screwed it in place. and then re soldered the wires back onto the switch. turned the bike on and......


works perfectly! and i didnt have to spend a dime! just the way i like it.

 

Huzzah! Glad to hear the patient survived and recovered nicely. Good on ya!