ninjaneer
Well-Known Member
So the inspiration behind this write-up comes from an incident in which I found myself pushing my bike a half-mile to the gas station because my Reserve Switch could not make the necessary connection that re-energizes the fuel pump relay, essentially disconnecting the fuel pump from the battery. Another bit of motivation was that darn sticky start button that even with some WD40 would still keep the headlight disconnected from the battery.
I initially wanted to document a process that covered the reconditioning of the components as well as continuity checks. However, this proved impossible due to the limitation on the number of attachments one can place in a single post. As such, I refer you to your preferred service manual that will get you to the point of accessing the fuel pump relay connector and the starter relay connector, so that you may perform continuity checks after the reconditioning.
I advise that you don't rely totally on my pictures as a reference during reassembly. Take pictures to record your own component placement and wire routing.
First things first, a parts list:
2) Once the throttle-side switch housing is off, back out the two screws that you more than likely had to loosen in order to slide the assembly off of the handlebar
3) Remove the top of the housing and back out the screw that holds down the inner white dust cover in the bottom of the housing.
4) Back out the screw that holds down the Fuel Reserve Switch Actuating Arm and remove the arm. Clean it up and shoot some liquid lube in the hinge.
5) Back out the screw that holds down the Wire Clamp (green arrow)
6) Remove the Fuel Reserve Switch (yellow arrow) and gently pull the locking tab out to dislodge the black contact plate
7) Using a pencil eraser rub off the corrosion on the contacts until bright and shiny, reassemble, and position the switch back in the housing.
NOTE: I forgot to take a picture of this, but there is a steel ball on the back of the switch--lube it up with a dab of grease.
8) Remove the Starter Switch (red arrow, pic 1) and gently pull the locking tab out to dislodge the contact plate (red arrow, pic 2). BE VERY VERY CAREFUL TO NOT LOSE THE STEEL BALL AND SPRING UNDERNEATH THE BUTTON (red arrows, pic 3) AND NOTE HOW THE BUTTON SPRING IS MOUNTED (green arrow, pic 3)
9) Using a pencil eraser rub off the corrosion from the contacts until bright and shiny. Grease up the underside of the start button, place a dab of grease on the steel ball, reassemble, and position the switch back in the housing.
10) In the top of the switch housing, back out the screw holding down the Engine Stop Switch button and dislodge it from the housing by pushing the "OFF" side of the button.
11) Pop the contact plate out by gently pulling on the locking tab and rub off the corrosion using the pencil eraser
12) Clean and grease the ball and swivel post. Reassemble and position the assembly back in the switch housing.
13) Perform continuity checks between the starter switch and the starter relay and between the fuel reserve switch and the fuel pump relay as outlined by your service manual.
I initially wanted to document a process that covered the reconditioning of the components as well as continuity checks. However, this proved impossible due to the limitation on the number of attachments one can place in a single post. As such, I refer you to your preferred service manual that will get you to the point of accessing the fuel pump relay connector and the starter relay connector, so that you may perform continuity checks after the reconditioning.
I advise that you don't rely totally on my pictures as a reference during reassembly. Take pictures to record your own component placement and wire routing.
First things first, a parts list:
- Your favorite Service Manual http://vmoa.net/VMX12-Service-Manual01.pdf
- Liquid lubricant of your preference (e.g., WD40)
- Non-liquid lubricant of your preference (e.g., grease)
- Pencil eraser
Click on each picture for an enlarged view
1) Because of the variety of handlebars out there, I leave it up to you to figure out how to slide the throttle-side switch housing off of the handlebar.
2) Once the throttle-side switch housing is off, back out the two screws that you more than likely had to loosen in order to slide the assembly off of the handlebar
3) Remove the top of the housing and back out the screw that holds down the inner white dust cover in the bottom of the housing.
4) Back out the screw that holds down the Fuel Reserve Switch Actuating Arm and remove the arm. Clean it up and shoot some liquid lube in the hinge.
5) Back out the screw that holds down the Wire Clamp (green arrow)
6) Remove the Fuel Reserve Switch (yellow arrow) and gently pull the locking tab out to dislodge the black contact plate
7) Using a pencil eraser rub off the corrosion on the contacts until bright and shiny, reassemble, and position the switch back in the housing.
NOTE: I forgot to take a picture of this, but there is a steel ball on the back of the switch--lube it up with a dab of grease.
8) Remove the Starter Switch (red arrow, pic 1) and gently pull the locking tab out to dislodge the contact plate (red arrow, pic 2). BE VERY VERY CAREFUL TO NOT LOSE THE STEEL BALL AND SPRING UNDERNEATH THE BUTTON (red arrows, pic 3) AND NOTE HOW THE BUTTON SPRING IS MOUNTED (green arrow, pic 3)
9) Using a pencil eraser rub off the corrosion from the contacts until bright and shiny. Grease up the underside of the start button, place a dab of grease on the steel ball, reassemble, and position the switch back in the housing.
10) In the top of the switch housing, back out the screw holding down the Engine Stop Switch button and dislodge it from the housing by pushing the "OFF" side of the button.
11) Pop the contact plate out by gently pulling on the locking tab and rub off the corrosion using the pencil eraser
12) Clean and grease the ball and swivel post. Reassemble and position the assembly back in the switch housing.
13) Perform continuity checks between the starter switch and the starter relay and between the fuel reserve switch and the fuel pump relay as outlined by your service manual.
14) Reassembly and installation are the reverse of disassembly and removal.
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