Starter button
The starter button on the 9 cracked off at the pivot, a few weeks ago. Just tossing out a cheap repair, for those of you who may have had this happen.
The button pivots on a small metal pin inside the switch assembly. The actual button itself is molded around this pin. When it cracks off, the button comes off in your hand (hopefully; not on the road!) and there's a small, maybe 1/8" piece of plastic on the back side of the pivot pin remaining (where it cracks-off.) Super-gluing the button back on the pivot to the plastic piece will hold about two weeks, if you're lucky. Take the 1/8" broken piece out with needle-nose pliers. Take your Dremel and a very fine burr ball, and "poke a hole" on the left (pivot) side of the button, on the top and bottom (where the outer plastic is very thin.) Take a very small zip tie and thread it through one outer hole on the button, then back behind the metal pivot pin, and back out through the other hole on the button. Getting the conical return spring to line up can be a PITA when you re-assemble, but can be done. Tighten the zip tie enough to hold the button onto the pivot, but loose enough to still "flex" on the pivot pin.
A cheap fix. (Personally, I would prefer a replaceable and accessible momentary-contact toggle switch, instead of 1/8" of plastic on a metal pivot pin, but I tend to like things over-engineered...... The fact that we depend on 1/8" of molded plastic for the starter button to work, kinda makes me think of all the places I could've been stranded, had it broken at the wrong time. Geeze. I feel safer using the zip-tie!)
The button pivots on a small metal pin inside the switch assembly. The actual button itself is molded around this pin. When it cracks off, the button comes off in your hand (hopefully; not on the road!) and there's a small, maybe 1/8" piece of plastic on the back side of the pivot pin remaining (where it cracks-off.) Super-gluing the button back on the pivot to the plastic piece will hold about two weeks, if you're lucky. Take the 1/8" broken piece out with needle-nose pliers. Take your Dremel and a very fine burr ball, and "poke a hole" on the left (pivot) side of the button, on the top and bottom (where the outer plastic is very thin.) Take a very small zip tie and thread it through one outer hole on the button, then back behind the metal pivot pin, and back out through the other hole on the button. Getting the conical return spring to line up can be a PITA when you re-assemble, but can be done. Tighten the zip tie enough to hold the button onto the pivot, but loose enough to still "flex" on the pivot pin.
A cheap fix. (Personally, I would prefer a replaceable and accessible momentary-contact toggle switch, instead of 1/8" of plastic on a metal pivot pin, but I tend to like things over-engineered...... The fact that we depend on 1/8" of molded plastic for the starter button to work, kinda makes me think of all the places I could've been stranded, had it broken at the wrong time. Geeze. I feel safer using the zip-tie!)
kinda makes me think of all the places I could've been stranded, had it broken at the wrong time. Geeze. I feel safer using the zip-tie!)
Will do. I didn't think about taking pics until after I had it re-assembled! I'll find a way; will hand draw if necessary. That OE starter button setup is amazingly fragile.
Made a sketch of the starter button assembly, since there was no exploded diagram in the shop manual.
The actual size of the plastic "eyelet" on the starter button is about 1/8". It will crack in half if pressure is applied to any forceful degree (like with gloves on) other than "straight-in" on the indented starter button symbol. If your button wiggles up and down, beware; make sure it's "square" in the socket before you apply pressure.
I'm guessing you would need to unscrew the halves of the assembly and replace the whole thing for a proper repair. Pretty serious rip-off for a 1/8" piece of plastic. At least the zip tie has a bit more nylon in the mix for tensile strength.
Hope this saves someone from being stranded.
The actual size of the plastic "eyelet" on the starter button is about 1/8". It will crack in half if pressure is applied to any forceful degree (like with gloves on) other than "straight-in" on the indented starter button symbol. If your button wiggles up and down, beware; make sure it's "square" in the socket before you apply pressure.
I'm guessing you would need to unscrew the halves of the assembly and replace the whole thing for a proper repair. Pretty serious rip-off for a 1/8" piece of plastic. At least the zip tie has a bit more nylon in the mix for tensile strength.
Hope this saves someone from being stranded.
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Daves_636
Ninja ZX-6R & ZX-6RR
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May 18, 2007 06:05 AM




