Author Topic: Broken wire in V50 III start switch  (Read 654 times)

Offline jamesfjamesf

  • New Egg
  • *
  • Posts: 58
Broken wire in V50 III start switch
« on: June 08, 2024, 04:52:00 PM »
I was hoping to start the bike tonight but when I pushed the starter button there was not even crickets. I traced the lack of zots up to the RH switch and when I opened it I found a wire loose. I can't tell if it's broken or just came out. Is anyone familiar with this type of switch? Is there a way to reconnect the wire? I did try to figure out how to remove the switch from the housing but that looked like a sure fire way to needing a new complete unit.

thanks,
jim



Offline Pistonbroke

  • New Egg
  • *
  • Posts: 6
Re: Broken wire in V50 III start switch
« Reply #1 on: June 09, 2024, 03:20:05 PM »
Its a good while since I've repaired one of these, but I recall the wire being riveted up via one of the tubular rivets on the back of the brass contact plate. Its possible to solder it back on, but is tricky due to the low melting point of the plastic. I would remove the remains of the crimp from the detached wire and make sure the strands are clean and unoxidized. I use a glass-fibre pencil to remove any surface corrosion. Tin the wire with tin/lead solder (unleaded requires a higher melting point). I like to add a little rosin flux gel used for electronics work to improve the flow. Now, here's the tricky bit - fold up a piece of abrasive paper and clean the underside of the brass contact plate on the right hand side. Once done, apply some flux underneath. Using a fine tipped, hot soldering iron angled to get just under the edge of the plate, heat it just enough to get it tinned underneath and on the edge. Hot and quick is the technique. I instantly cool the area with freeze spray. You need to beat the thermal creep that will soften the plastic. Apply some more flux to the wire and get it positioned under the plate ready to solder - I use Blu Tack to leave both hands free. You want a little bit of wire exposed. Heat the wire and feed in some solder on the junction. Work quickly and cool down the area immediately afterwards.

The wire breaks because of ineffective strain relief. Once soldered up and the wires secured, a good repair will last indefinitely. My Wife's old V50III still has the repair I did back in 1990. 


Online pehayes

  • Gaggle Hero
  • *****
  • *
  • *
  • *
  • *
  • *
  • Posts: 4653
    • Falcone Touring
Re: Broken wire in V50 III start switch
« Reply #2 on: June 09, 2024, 03:46:07 PM »
Soldering will surely risk the plastic.  This might be a good case for using conductive epoxy (not cheap) instead of heat.  Start searching for a replacement switch from another parted out bike.  There is a smallblock forum that might give better part search results.

https://www.amazon.com/gp/product/B08K3TG5D9/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

Patrick Hayes
Fremont CA

Offline Pistonbroke

  • New Egg
  • *
  • Posts: 6
Re: Broken wire in V50 III start switch
« Reply #3 on: June 10, 2024, 02:44:12 AM »
It does risk the plastic - that's why I say it's a tricky repair due to the low melting point of the plastic and advise the use of freeze spray. The success or otherwise comes down to the skill and equipment of the person doing the repair, but offer this up as a method that's worked for me.

Wildguzzi.com

Re: Broken wire in V50 III start switch
« Reply #3 on: June 10, 2024, 02:44:12 AM »

Offline jamesfjamesf

  • New Egg
  • *
  • Posts: 58
Re: Broken wire in V50 III start switch
« Reply #4 on: June 10, 2024, 12:22:18 PM »
I'm not a patient or precise solderer, even though I have a good iron, but I'll give it a shot, thanks.

I don't mind replacing with non-OEM. Back in the day there were tons of Ducati options on ebay, not so much anymore.

MG Cycles has a nice K&S ($140 for the pair - the left will have to patch  :grin:) or a bargain set for $60/pair, but will I just be buying more crap with those? Oh yea I'll also need a throttle assembly since it's bonded to the switchgear.

The last 5% of a project always takes as long as the first 95%...

jim

Offline jamesfjamesf

  • New Egg
  • *
  • Posts: 58
Re: Broken wire in V50 III start switch
« Reply #5 on: June 10, 2024, 07:32:55 PM »
Its a good while since I've repaired one of these, but I recall the wire being riveted up via one of the tubular rivets on the back of the brass contact plate. Its possible to solder it back on, but is tricky due to the low melting point of the plastic.

The wire breaks because of ineffective strain relief. Once soldered up and the wires secured, a good repair will last indefinitely. My Wife's old V50III still has the repair I did back in 1990.

I couldn't see a way to solder anything on to the back of that plate. It sits flush against the plastic and while maybe I could bend it up, that would leave me with the same possible shorting out against the bars that soldering on top would do, so I just soldered it on top. It looks like there's enough clearance so it won't short against the bars but I wrapped some electrical tape around them to be safe. It worked!

The other wire is half frayed and if that breaks I'll just mount a doorbell style push button to the bars for starting, at least until the winter.

jim



 

***Wildguzzi Official Logo High Quality 5 Color Window Decals Back In Stock***
Shipping in USA Only. Awesome quality. Back by popular demand. All proceeds go back into the forum.
Best quality vinyl available today. Easy application.
Advertise Here