LeMans One question... switch gear

[Cal3Me]

I need help with removing the clutch side switch gear & wiring on a Lemans 1 to replace the broken clutch lever bracket. Tips & tricks please 

[guzzisteve]

If you are changing the perch it must be a rotating sw like on a T.   Unplug pin conn out of Molex going to sw.  They usually feed in & out a hole in bar or clip-on. Silicone spray & patience.

If you can't do it, take it to Joe.

[Cal3Me]

Yep.... it's like a T-bike. Sliding the wires out far enough to get to the end of the clip-on looks like the hard part? Removing the wires from the molex and pulling them out of the clip-on...huh? Nothing is easy ..
Thanks buddy   

[Carlo DeSantis]

Yep.... it's like a T-bike. Sliding the wires out far enough to get to the end of the clip-on looks like the hard part? Removing the wires from the molex and pulling them out of the clip-on...huh? Nothing is easy ..
Thanks buddy 

Tim,

There's a removal tool that makes it easy to get the leads out of the Molex connector.  I have one if you want to borrow.

Best,

Chuck

[Cal3Me]

chuck...... I found a funny looking tool in a box of mine and was told it's a Molex tool. There are 4 different size sleeves on it that slide over the pins. Thanks for the offer ,,

[leafman60]

As a side note, if you don't have the official molex tool, you can improvise one with some brass tubing from a hobby store.

Select the size that just slips over the pins or sleeves.  You can slightly crimp the end of the tube if you need more squeeze on the lock tabs.

[Two Checks]

Beware the locking tabs on the pins can and do break off when extracting them.

[canuck750]

Identical clip-ons and switches on the 750 S3, I removed the connector block end first, then pulled off the plastic sheathing, slowly pushed the wires up and out through the bars.

I recommend buying new PVC sheathing and spritz some glass cleaner or dish detergent / water into the PVC and then push the wires through. MG Cycle sells new rubber boots that cap the end of the clip-ons as well.

The switches are delicate and it's a good time to get some brake cleaner and wash them out. I cleaned up the brass parts inside the switch with a fine file and brass brush then some electrical grease.



The head light switch locks into a recess in the clutch perch and the switch into a recess in the light switch.