Topic: Head Light switch reassembly of the slide ball bearing problems

[newday777]

Has anyone put in new guts from aftermarket switches into old switch cases? I bought new switches from a couple of different suppliers and have had problems of the cases being too tight over the throttle tube causing binding of the throttle when tightened properly, so I got a good used set of K4 cases(had bad wires and switches)to put in the new guts.
I'm having a hard time getting the headlight switch spring and ball bearing back into the case because of the tight quarters of the case. I've tried using big, wide tweezers as well as my fat fingers (Scotsman).....
Any how to's to help out?

[seanbarney41]

I did it before.  I don't remember how.  I do remember it took 2 lost balls before the third made it back in there and that it was several years ago and I have not attempted it again.

[newday777]

I found 1 of 2 that flew off.....

[grcamna2]

I found 1 of 2 that flew off.....

The switch comes with two ball bearings inside;one(larger?)for the headlight switch slide bar and the other one(smaller I think)for the red top kill switch. So far I haven't lost one.. knock on wood.

[newday777]

I found 1 of 2 that flew off.....

The switch comes with two ball bearings inside;one(larger?)for the headlight switch slide bar and the other one(smaller I think)for the red top kill switch. So far I haven't lost one.. knock on wood.

Yes 2 different bearings.
The headlight slide bearing is the problem, holding the bearing in against the case and spring pushing in the tension as you try to get the contact plate slid into position.

[zabzob]

I used a glob of dielectric grease to hold it in place while I slid it into place. The kill switch part was not difficult, the headlight switch significantly more so.

[newday777]

Yes I've slathered dielectric grease on multiple times and as you said the kill switch was a breeze.

[Flyin900]

It's been awhile since did any of these and I think the surface is vertical that your trying to slide that gremlin into???
The grease and I believe I used a very thin jeweller's flat blade screwdriver blade to hold the ball and spring compressed into the socket in the housing while pushing the assembly down into the slotted grooves that hold it in place.

With the parts not OEM entirely, there maybe some fit issues that cannot be solved with the above option. 

[CycleRanger]

It's been awhile since did any of these and I think the surface is vertical that your trying to slide that gremlin into???
The grease and I believe I used a very thin jeweller's flat blade screwdriver blade to hold the ball and spring compressed into the socket in the housing while pushing the assembly down into the slotted grooves that hold it in place.

With the parts not OEM entirely, there maybe some fit issues that cannot be solved with the above option. 

I just did a rebuild recently on my CL350 controls and yeah, it sucks.
I had to replace the slider plastic piece for the hi/lo beam and it was a bugger getting it all back in place.
I had the best luck with a thin set of tweezers.

Also, if you have the controls completely apart like I did make sure the correct spring is in the correct place.

[newday777]

It's been awhile since did any of these and I think the surface is vertical that your trying to slide that gremlin into???
The grease and I believe I used a very thin jeweller's flat blade screwdriver blade to hold the ball and spring compressed into the socket in the housing while pushing the assembly down into the slotted grooves that hold it in place.

With the parts not OEM entirely, there maybe some fit issues that cannot be solved with the above option. 

I just did a rebuild recently on my CL350 controls and yeah, it sucks.
I had to replace the slider plastic piece for the hi/lo beam and it was a bugger getting it all back in place.
I had the best luck with a thin set of tweezers.

Also, if you have the controls completely apart like I did make sure the correct spring is in the correct place.

Thanks. I'll be rechecking the springs next time I get in the shop.
Do you have pictures of your tweezers? I bought a couple at the local Ace hardware store.

[CycleRanger]

It's been awhile since did any of these and I think the surface is vertical that your trying to slide that gremlin into???
The grease and I believe I used a very thin jeweller's flat blade screwdriver blade to hold the ball and spring compressed into the socket in the housing while pushing the assembly down into the slotted grooves that hold it in place.

With the parts not OEM entirely, there maybe some fit issues that cannot be solved with the above option. 

I just did a rebuild recently on my CL350 controls and yeah, it sucks.
I had to replace the slider plastic piece for the hi/lo beam and it was a bugger getting it all back in place.
I had the best luck with a thin set of tweezers.

Also, if you have the controls completely apart like I did make sure the correct spring is in the correct place.

Thanks. I'll be rechecking the springs next time I get in the shop.
Do you have pictures of your tweezers? I bought a couple at the local Ace hardware store.

The tweezers. Nothing special.

[newday777]

It's been awhile since did any of these and I think the surface is vertical that your trying to slide that gremlin into???
The grease and I believe I used a very thin jeweller's flat blade screwdriver blade to hold the ball and spring compressed into the socket in the housing while pushing the assembly down into the slotted grooves that hold it in place.

With the parts not OEM entirely, there maybe some fit issues that cannot be solved with the above option. 

I just did a rebuild recently on my CL350 controls and yeah, it sucks.
I had to replace the slider plastic piece for the hi/lo beam and it was a bugger getting it all back in place.
I had the best luck with a thin set of tweezers.

Also, if you have the controls completely apart like I did make sure the correct spring is in the correct place.

Thanks. I'll be rechecking the springs next time I get in the shop.
Do you have pictures of your tweezers? I bought a couple at the local Ace hardware store.

The tweezers. Nothing special.

The smaller ones, left have pointed ends.
The longer have @ 1/4" wide ends.
I'm thinking about doing some modifications like bending the ends in a few degrees to grab more parallel to each other ends.

[newday777]

Well another got away....... it'll turn up someday.....
Today I ordered 100 4mm Stainless Steel ball bearings.... when they get here, that's probably when the others will return from their jaunt.....🤔

[CycleRanger]

Well another got away....... it'll turn up someday.....
Today I ordered 100 4mm Stainless Steel ball bearings.... when they get here, that's probably when the others will return from their jaunt.....🤔

Good luck, I've been waiting ten years for a kick starter ball bearing I lost to turn up.

[newday777]

Well another got away....... it'll turn up someday.....
Today I ordered 100 4mm Stainless Steel ball bearings.... when they get here, that's probably when the others will return from their jaunt.....🤔

Good luck, I've been waiting ten years for a kick starter ball bearing I lost to turn up.

Now that is being patient 🙌

[M 750K6]

 
I specialise in carb needle C-clips.

[newday777]

I specialise in carb needle C-clips.

As in In Flight Clips??

[Floshenbarnical]

At least you didn't drop your ball bearing down a blind bolt hole. I never got that one out

[seanbarney41]

I specialise in carb needle C-clips.

As in In Flight Clips??

ha ha yeah!  At least piston pin clips are big enough that they make a sound every time they bounce off something.  Doesn't mean you are ever gonna find it...but at least you have that hope!

[newday777]

OK I now have 100 4mm ball bearings so if you loose yours, let me know.
Now to find those other 2 that went airborne.....🤔