Starter Switch - Remove and Replace??

My question is how can I remove the starter/on-off switch on my 1985 Interceptor. For me, the throttle cables seem to be the issue. I can't remove them in order to completely remove the switch. I can't slide the housing off the handle bar either because there isn't enough slack in the throttle cables.

At first, the starter switch only worked occasionally, then not at all. The last time I tried it smoke started rising out of the housing. The headlight doesn't work now either. I think the contacts must be fused and are not sliding back in position to allow contact with the headlight contacts. Once I can remove the switch, installing a new one shouldn't be a problem.

Thanks for the help!

 

I think the best thing for you is disconnect throttle cables at the carbs, then you can release top of cable from grip. Requires lifting tank off (I turn mine around 180 degrees and rest on back of bike), remove airbox, only five screws. Then take off your front fairing to get at wiring under headlight. Undo cable to switch assembly and remove from handle bars. Much easier to work on delicate switch components. Work on switch on table top where you can see any parts that might pop off.

 

Just be careful!

Though I have not done this myself, and it may not be an issue with your gen bike, one of our resident experts, Toecutter, warned me that buried inside the 6th gen switch assembly, are small check balls and springs that fly off when you open them up. Finding them on a garage floor is near impossible.

 

I don't remember that while inside my 6th gen, in fact, my switches were all held into the housing with screws and the such. I had to remove the switch and the components were modular ... but good advice none the less, I always take switches / housings apart gingerly in the event of such a catastrophe.

 

I have rebuilt mine, and that is why I suggested doing on a table on an old cloth to keep parts from disappearing. There is a spring loaded ball and detent spring, if you are lucky it will be sticky with old grease and not fly out. Tedious but not difficult job. If you try and do it on the bike and you drop a part, it's going to be difficult to find. Switch is integral to housing and not a self contained switch.

 

Wierd. Mine was modular in the housing and two screws had to be removed inside the housing before you could pull it??

 

I think Allyance's suggestion regarding the throttle cables sounds correct, but as an alternative could you remove the clip-on off the forks (need to remove the brake master as well) and then slip that out of the throttle housing?

 

I think I removed the clip on along with the master cylinder to install my "euro-trash" head-light ON OFF switch. Its all good in the neighborhood

 

That might be what TC was warning me of. Not sure. One of these days I have to take apart my hazard light switch cause it stopped working many years ago.

 

My problem was a plastic part that broke and I had to rebuild with JB Weld, took some fussing getting it to rock properly. Cleaned contacts as well, but they weren't the problem.

 

When I installed the rebuilt carbs I had a hell of a time installing the throttle cables on the carbs. I don't want to revisit that because I think I would have to remove the carbs again to attach the cables.

 

If you remove the throttle tube from the switch housing and pull the switch housing assembly free from the bar with the wires you can unscrew one of the cables from the bottom and then spin the housing off the other cable. Way easier than pulling the cables from the bike.

 

Can't seperate the throttle cables from the housing. The cables run through the housing and then connect to the throttle tube. Doesn't seem to be enough slack in the cables to just remove them from the sleeve.

 

I think the cable with the nut has the slack adjuster on it, can you adjust some slack into it?

 

I'll check it out today.

 

Hey. You got your brutha to sign up here Toe?

 

Now that I think about it, there may not be a small ball, but just the small return spring that goes on the plastic piece I repaired.

 

I tried removing the left clip-on unsuccessfully. I loosened the pinch bolt and and nut/fork tube cap and the clip-on wouldn't budge. Does it need "persuasion"?

 

I'm not sure about an 85 model, but all recent Hondas I've seen have a thin wire circlip set in a groove in the top of the fork tube that will stop the clip on sliding up off. However even if that is in place the clip on should now feel a little loose. If it's seized on you might need to persuade it.


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Finally got the switch off the handlebar. There was a circlip holding the clip-on in place. After removing it and with some help with the persuader the clip-on came off and I could slide the switch housing and throttle sleeve off the bar and remove the switch.

Now it's only a matter of finding another switch.

Thanks for the help!