Busted Volume switch- source for new?
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From: Phoenix '53, '88, '09 Big Twins
Busted Volume switch- source for new?
arghh, busted vol switch on 09 FLHTC.
the same switch is used 1998~2013
71810-08
Superceded from: 71619-98
anyone know of an aftermarket (meaning less expensive) source ?
for those who have been there, the cap came off, the contact plate on the plunger...one of the contacts was folded under, and scratched up the contacts----so a crap part from new.
straightened it, cleaned up the contact plates and am epoxying it together- but I'll need a switch at some point.
Cheap source would be good
Mike
the same switch is used 1998~2013
71810-08
Superceded from: 71619-98
anyone know of an aftermarket (meaning less expensive) source ?
for those who have been there, the cap came off, the contact plate on the plunger...one of the contacts was folded under, and scratched up the contacts----so a crap part from new.
straightened it, cleaned up the contact plates and am epoxying it together- but I'll need a switch at some point.
Cheap source would be good
Mike
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Joined: Nov 2006
Posts: 5,895
Likes: 1,909
From: East Coast, USA
Not aware or have heard of any aftermarket source. Just this past spring the mode select switch on my Ultra failed. The mode of operation on the Harman-Kardon radio (FM/AM/Weather/CD, etc) would jump around when I pressed the switch. Turned out the switch was broken by the plunger. Ordered a new switch from one of the HD Internet sites (Boardtracker). I didn't want to solder the new switch in, so removed the pins from the connector and crimped new pins onto the new switch. Then ran the wires through the conduit. Not a difficult job, but a bit tedious. You'll probably need to remove the fairing cap. I initially tried to remove the wires without removing the fairing cap and I wasn't able to do it.
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From: Phoenix '53, '88, '09 Big Twins
Thanks- That is helpful.
I much prefer your approach than crowding connectors in the shell- ( although a flhtc doesn;t have PTT- or whichever other button is over there.
exopy worked on the shell and back together, but the damaged contact plate from teh mis-assembly at manufacture makes for fiddly operation.
so a stop gap.
when you say fairing cap- do you mean outer fairing?
Thanks, Mike
I much prefer your approach than crowding connectors in the shell- ( although a flhtc doesn;t have PTT- or whichever other button is over there.
exopy worked on the shell and back together, but the damaged contact plate from teh mis-assembly at manufacture makes for fiddly operation.
so a stop gap.
when you say fairing cap- do you mean outer fairing?
Thanks, Mike
Last edited by mkguitar; Dec 6, 2016 at 11:35 AM.
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From: East Coast, USA
No, I was referring to the inner fairing cap assembly (58510-96). You'll need to remove the ignition switch **** and use that ignition switch alignment tool, etc
Plus as you mentioned, the outer fairing needs to be removed.
I found the conduit inside the fairing was zip tied at various spots and I couldn't remove the conduit easily without removing the inner fairing cap assembly.
Plus as you mentioned, the outer fairing needs to be removed.
I found the conduit inside the fairing was zip tied at various spots and I couldn't remove the conduit easily without removing the inner fairing cap assembly.
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From: Phoenix '53, '88, '09 Big Twins
Thanks- I have a black belt at fairing cap removal!
You have halfed the time I'll need for this fix
Mike
You have halfed the time I'll need for this fix
Mike
Last edited by mkguitar; Dec 6, 2016 at 04:20 PM.
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From: Phoenix '53, '88, '09 Big Twins
For the next guy:
the cap the plunger runs through came off.
model airplane cement and superglue failed to hold this- a 2 part epoxy is holding- clear any glue away from the 2 ridges in the sides- these are used to mount the switch.
if your little 1/4" contact plate comes loose ( as mine did) the rounded end fits into a slot on the white part of the plunger, this has a bend so it acts as a spring and the 2 **** stick up.
to ease placement of the plunger into the switch body, i cut a strip of aluminum from a can, and used that to line the contact plate side of the switch body, and the plunger went in without hanging up- remove the strip.
turn on radio and check function...
add glue and a couple of rubber bands to hold it all together.
wait- reassemble
-------------------------------------------------------------------------
A pal of mine at a dealer found a switch in the take off pile and it's coming to me free- it's the -98 version and I wonder if that may be superior to the -08
Mike
the cap the plunger runs through came off.
model airplane cement and superglue failed to hold this- a 2 part epoxy is holding- clear any glue away from the 2 ridges in the sides- these are used to mount the switch.
if your little 1/4" contact plate comes loose ( as mine did) the rounded end fits into a slot on the white part of the plunger, this has a bend so it acts as a spring and the 2 **** stick up.
to ease placement of the plunger into the switch body, i cut a strip of aluminum from a can, and used that to line the contact plate side of the switch body, and the plunger went in without hanging up- remove the strip.
turn on radio and check function...
add glue and a couple of rubber bands to hold it all together.
wait- reassemble
-------------------------------------------------------------------------
A pal of mine at a dealer found a switch in the take off pile and it's coming to me free- it's the -98 version and I wonder if that may be superior to the -08
Mike
Last edited by mkguitar; Dec 7, 2016 at 01:55 PM.
Thread Starter
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Extreme HDF Member
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From: Phoenix '53, '88, '09 Big Twins
Alright new switch arrived and my "fix" was hinky- I think the bent contact plate wasn;t staying in place.
today was nat'l open up the fairing day and I had accumulated a list of tasks under the hood.
replace switch, swap speakers, install hdpdplus & strip out my old iSimple ipod interface and rotate my bars a bit.
the instructions to replace switch in the manual have the old wires cut near the switch and the new switch wires soldered on, shrink and route the wires so they'll fit in teh housing- I do not solder on vehicles and have learned the hard way this don;t work well over time.
So...snipped the wires at the old switch. the wires with the new switch are plenty long- I stripped each back 1/2" and soldered pink to pink green to green etc, and pulled the new wires through the sheath .
once I had everything pulled through and put the controls back together ala manual, I cut each of the 8 wires to about 3". stripped and crimped 4 times, and taped up the bundle with a tie wrap to keep it all tight.
on to next projects...
mike
today was nat'l open up the fairing day and I had accumulated a list of tasks under the hood.
replace switch, swap speakers, install hdpdplus & strip out my old iSimple ipod interface and rotate my bars a bit.
the instructions to replace switch in the manual have the old wires cut near the switch and the new switch wires soldered on, shrink and route the wires so they'll fit in teh housing- I do not solder on vehicles and have learned the hard way this don;t work well over time.
So...snipped the wires at the old switch. the wires with the new switch are plenty long- I stripped each back 1/2" and soldered pink to pink green to green etc, and pulled the new wires through the sheath .
once I had everything pulled through and put the controls back together ala manual, I cut each of the 8 wires to about 3". stripped and crimped 4 times, and taped up the bundle with a tie wrap to keep it all tight.
on to next projects...
mike
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From: Lake, Ms
Good write up Mike. This project is quite a bit harder to do when the bars are wired internally. Hopefully I've broken my last one.
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