You would not believe how much this video helped me. Need to rebuild my switch with missing parts. made the starter PCB and over plate simply by pausing the video at the right time. Thanks for sharing the good info!
One of the best videos I've found on this. I work on small electronics and I was trying to find a diagram of the internals, the real thing is the best teacher, thanks man.
Wow mate, you have the patience of Job to disassemble and then reassemble all those fiddly tiny bits of switchgear! Very nice work, and amazing that you made it so informative and interesting to watch.
I should have a masters degree in soldering with the amount of research I've done and fancy gear I've collected , bit I'm still rubbish at it ! Great job Andy , really rewarding video ! 👍🏻☮❤ Peace and love brother 🤗
Seamstresses stitch ripper is the ideal tool for sagely cutting loom tape and sheathing without damage to the wires. It also reduces the risk of claret escaping from your body 👍
@@AndyMechanic Hi Andy had to do the exact same job on my 500/4 only i find it safer to cut away from me rather than towards my thumb lol gr8 video & what a pain of a job it is to do.
That was really interesting, thankyou so much for being so thorough, I really learned a lot and am now kinda looking forward to fixing the switches on my Ducati. When I turn to full lock the bike cuts out, so that doesn't seem normal at all 😀
Thanks. The problem on your Ducats is likely to be a broken wire in the loom as it flexes past the steering head bearings - very common. Good Luck. Cheers Andy
Yes it did, however, as the ignition Primary circuit current originally ran through the kill switch there was an unacceptable volt drop in that switch which was highlighted during the inspection of the circuit. This is why this switchgear was overhauled. Cheers Andy
I already saw those Yellow insulation tapes on brand new factory wirings, those are like quality control marks on the production line. I saw those on cars and scooters too (like my Vespa that I bought brand new so the wiring was untouched).
Hi andy . Just watched this as my little start button is givin me a mental headache . On that contact that u attatched yellow wire ,i have a green earth wire to . I didnt have a keeper plate like yours to hold in place. Now when i turn key on starter moter ingages . Ive swapped wires to solder points . Maby 10 hours of trial n error . Very frustrating . I mite try find snd hand unit and rob the parts im missing.
hi Andy your right there is a BIG plate missing that (holds the wires back) and it holds the light plate in place its L shaped and 32 mm x 20 mm it covers the area where the missing ball was not sure if it stops that dropping out though ? keep up the good work
Hello mate , I’ve commented before asking for advice on my kmx 125 , i was wondering if you could help me with this. It starts when I hold my hand over the carb intake , but when I put the air box boot back on it doesn’t go , I’ve messed about with the air screw and it’s made no difference. I do have a “make shift” air filter in it tho , a sock round the actual plastic where the filter slides on , but I thought that would not make a difference.
It sounds like it's running way too lean. Using a sock for an air filter is going to offer less resistance to air flow causing a lean mixture. Worse still it won't filter out the dust which will enter the cylinder & cause significant damage. My suggestion is refit the stock air filter with a new filter element which is oiled in the usual way. Don't forget to grease the mating surface to get a good seal. Once that's done see if the poor starting is fixed. Cheers Andy
One quick question if you don't mind, what wireless soldering iron are you using, as I need to replace mine. Yours looks to be also better then the one I had.
Hi Bob, sure thing, is a gas powered soldering iron made by Dremel. Comes in a nice metal tin with lots of accessories too. I'd highly recommend it. Cheers Andy
@@AndyMechanic Thanks so much, Andy. I couldn't quite make out the brand, but I do realize that wasn't point of the video. I did see that you could remove the tip and use as a heat gun for heat shrink which I thought was brilliant. The one I had for many years and lasted, could replace the tip only.
I can't believe you are a tutor at one of our technical institutions. You lost parts on disassembly and mist out a spring on assembly. All you needed to do was slip the heatshrink onto the original kill switch wire's. I just hope the spring from the kill switch is replaced underneath the contact in the rotating part of the switch. Loss terminals on relays ???
Erm....if your been bothered to watch the complete video you would have noticed the cable clamp was already missing. Seriously, people like you, who try find fault & complain instead of doing your best to make the World a better place, really, really piss me of. Best you head off & find a different UA-cam creator to annoy.
Hey, I wasn't talking about any cable clamp, I was talking about the ball bearing in the hi/lo switch for the lights and the spring you left out of the on-off switch for ignition power. I am a mechanic and I have worked on many restorations of many different British classics including their three most popular Motorbike brands. Lucus switch gear are far more complicated than Honda, regardless of brand you can't lose or break stuff on a restoration because it then becomes just another rebuild with all NEW parts. I found it hard to watch you reassemble the switch with the spring missing and replacement balls that were obviously not the correct size. I have also been asked to teach at a large institution but as you will know, those that can, do and those that cant, teach. I never said I didn't enjoy watching you doing the job. Its always interesting watching someone doing the same thing that you also love to do and learn from someone else's experiences. Have a good day and chear the f..k up. Have a pie.
You would not believe how much this video helped me. Need to rebuild my switch with missing parts. made the starter PCB and over plate simply by pausing the video at the right time. Thanks for sharing the good info!
One of the best videos I've found on this. I work on small electronics and I was trying to find a diagram of the internals, the real thing is the best teacher, thanks man.
Wow mate, you have the patience of Job to disassemble and then reassemble all those fiddly tiny bits of switchgear! Very nice work, and amazing that you made it so informative and interesting to watch.
You have so much patience. You have convinced me to never attempt to take apart one of my handle bar switches. You are fantastic.
Lol!
I should have a masters degree in soldering with the amount of research I've done and fancy gear I've collected , bit I'm still rubbish at it !
Great job Andy , really rewarding video !
👍🏻☮❤ Peace and love brother 🤗
Thank You.....it was a loooonnnggg video to make! Lol
Hi Andy, I always use some thick Silicone grease between the spring and the ball bearing to „glue“ the ball into place. Good work!
Mr.Young excellent video and thanks for sharing. That soldering iron tip definitely needs some tender loving care. Cheers Artie
It does! :-(
Really helpfull vid just about to rebuild my switch.so really usefull info.
Excellent job as always. Keep it up Andy
Thank you for the vid. Very nice
Well i very much enjoyed this video. Actually thourght Mechanic/watch maker. Very good job.
Seamstresses stitch ripper is the ideal tool for sagely cutting loom tape and sheathing without damage to the wires. It also reduces the risk of claret escaping from your body 👍
Lol. Yes, I saw Eric O using one - still need to remember to pick one up next time I pop into my local dress making shop! Lol
@@AndyMechanic Hi Andy had to do the exact same job on my 500/4 only i find it safer to cut away from me rather than towards my thumb lol gr8 video & what a pain of a job it is to do.
Sure is! No blood for me though....was lucky :-)
Cheers Andy
That was really interesting, thankyou so much for being so thorough, I really learned a lot and am now kinda looking forward to fixing the switches on my Ducati. When I turn to full lock the bike cuts out, so that doesn't seem normal at all 😀
Thanks. The problem on your Ducats is likely to be a broken wire in the loom as it flexes past the steering head bearings - very common. Good Luck. Cheers Andy
a good depth vid andy showing the ball ache of getting the switch gear out .get your self some disordering wick tho
Yes, I need to get some. I'll put it on the list together with the JIS screw drivers :-)
@@AndyMechanic wen that parcel arives you can cross jis off the list
does the engine not stop when you turn the key? killswich?
I believe it did, but to pass certain inspections the Emergency Kill Switch needs to work.
Yes it did, however, as the ignition Primary circuit current originally ran through the kill switch there was an unacceptable volt drop in that switch which was highlighted during the inspection of the circuit. This is why this switchgear was overhauled.
Cheers Andy
I already saw those Yellow insulation tapes on brand new factory wirings, those are like quality control marks on the production line. I saw those on cars and scooters too (like my Vespa that I bought brand new so the wiring was untouched).
Well I'd certainly hope the Honda lads soldering skills have improved! Lol
Hi andy . Just watched this as my little start button is givin me a mental headache . On that contact that u attatched yellow wire ,i have a green earth wire to . I didnt have a keeper plate like yours to hold in place. Now when i turn key on starter moter ingages . Ive swapped wires to solder points . Maby 10 hours of trial n error . Very frustrating . I mite try find snd hand unit and rob the parts im missing.
hi Andy your right there is a BIG plate missing that (holds the wires back) and it holds the light plate in place its L shaped and 32 mm x 20 mm it covers the area where the missing ball was not sure if it stops that dropping out though ? keep up the good work
Does it matter which terminal you solder which wire to? It's just a switch right? Does it care about directionality of current?
No, if it's only a basic 2 wire switch then either way should be fine provided switch is insulated from the switchgear body. Cheers Andy
Hello mate , I’ve commented before asking for advice on my kmx 125 , i was wondering if you could help me with this. It starts when I hold my hand over the carb intake , but when I put the air box boot back on it doesn’t go , I’ve messed about with the air screw and it’s made no difference. I do have a “make shift” air filter in it tho , a sock round the actual plastic where the filter slides on , but I thought that would not make a difference.
It sounds like it's running way too lean. Using a sock for an air filter is going to offer less resistance to air flow causing a lean mixture. Worse still it won't filter out the dust which will enter the cylinder & cause significant damage. My suggestion is refit the stock air filter with a new filter element which is oiled in the usual way. Don't forget to grease the mating surface to get a good seal.
Once that's done see if the poor starting is fixed.
Cheers Andy
My old eyeballs struggled even on my big screen.
One quick question if you don't mind, what wireless soldering iron are you using, as I need to replace mine. Yours looks to be also better then the one I had.
Hi Bob, sure thing, is a gas powered soldering iron made by Dremel. Comes in a nice metal tin with lots of accessories too. I'd highly recommend it. Cheers Andy
@@AndyMechanic Thanks so much, Andy. I couldn't quite make out the brand, but I do realize that wasn't point of the video. I did see that you could remove the tip and use as a heat gun for heat shrink which I thought was brilliant. The one I had for many years and lasted, could replace the tip only.
My bike had some white take on both sides from factory. I left it there.
miss the intros andy 🥺
Unfortunately, that's the way the wiring was done back then, through the handle bars. My CB 500 that I had was done the same way.
I can't believe you are a tutor at one of our technical institutions. You lost parts on disassembly and mist out a spring on assembly. All you needed to do was slip the heatshrink onto the original kill switch wire's. I just hope the spring from the kill switch is replaced underneath the contact in the rotating part of the switch.
Loss terminals on relays ???
Erm....if your been bothered to watch the complete video you would have noticed the cable clamp was already missing.
Seriously, people like you, who try find fault & complain instead of doing your best to make the World a better place, really, really piss me of.
Best you head off & find a different UA-cam creator to annoy.
Hey, I wasn't talking about any cable clamp, I was talking about the ball bearing in the hi/lo switch for the lights and the spring you left out of the on-off switch for ignition power.
I am a mechanic and I have worked on many restorations of many different British classics including their three most popular Motorbike brands. Lucus switch gear are far more complicated than Honda, regardless of brand you can't lose or break stuff on a restoration because it then becomes just another rebuild with all NEW parts. I found it hard to watch you reassemble the switch with the spring missing and replacement balls that were obviously not the correct size.
I have also been asked to teach at a large institution but as you will know, those that can, do and those that cant, teach.
I never said I didn't enjoy watching you doing the job. Its always interesting watching someone doing the same thing that you also love to do and learn from someone else's experiences.
Have a good day and chear the f..k up. Have a pie.
I forgot my, good job,? Sorry sorry.