Having successfully solved 2 common problems recently, I thought I'd post a summary here to save future DIY'ers time browsing through all of the threads. My 2 problems were:
-Stripped out set-screw on my throttle handle resulted in loose / freely rotating throttle knob.
-The integrated TAPS switch ended up non-functional as a result of problem #1
Here are the steps I took to solve the problem:
Handle Replacement:
1.) Cut off old TAPS switch (3 wires) as close to the switch as possible. Take a picture of the wire configuration first so you can rewire properly with the new switch.
2.) Remove throttle handle.
3.) Drill and tap a new hole with 1/4"-20 threads in the handle.
4.) Re-secure handle using 1/4"-20 x 1/2" long stainless steel set screw (I found mine at Fastenal). I also put marine-grade epoxy on the threads of the set screw.
TAPS Switch Replacement
1.) Purchase this switch: http://www.mouser.com/Search/Product...62111481-0-0-N They are cheap so buy a few of them in case you melt one or two during soldering!
2.) Strip a short section of wire on each of the 3 wires approximately the same length as the solder terminal.
3.) I could not make a mechanical connection prior to soldering because the hole in the solder lug terminals was smaller than the wire OD. To make the solder connection, I held the wire to the solder lug with very small tweezers and had a friend make the solder connection while I held it. There is no way I could have done this by myself with only 2 hands as there is very little slack in the wires.
4.) Repeat solder connections for the other 2 wires and gently snap the new TAPS switch back into place.
I'm not convinced this is a perfect solution long-term without mechanical connections on the TAPS switch, but time will tell. As of now, the handle is rock-solid and the new TAPS switch works perfectly!
-Stripped out set-screw on my throttle handle resulted in loose / freely rotating throttle knob.
-The integrated TAPS switch ended up non-functional as a result of problem #1
Here are the steps I took to solve the problem:
Handle Replacement:
1.) Cut off old TAPS switch (3 wires) as close to the switch as possible. Take a picture of the wire configuration first so you can rewire properly with the new switch.
2.) Remove throttle handle.
3.) Drill and tap a new hole with 1/4"-20 threads in the handle.
4.) Re-secure handle using 1/4"-20 x 1/2" long stainless steel set screw (I found mine at Fastenal). I also put marine-grade epoxy on the threads of the set screw.
TAPS Switch Replacement
1.) Purchase this switch: http://www.mouser.com/Search/Product...62111481-0-0-N They are cheap so buy a few of them in case you melt one or two during soldering!
2.) Strip a short section of wire on each of the 3 wires approximately the same length as the solder terminal.
3.) I could not make a mechanical connection prior to soldering because the hole in the solder lug terminals was smaller than the wire OD. To make the solder connection, I held the wire to the solder lug with very small tweezers and had a friend make the solder connection while I held it. There is no way I could have done this by myself with only 2 hands as there is very little slack in the wires.
4.) Repeat solder connections for the other 2 wires and gently snap the new TAPS switch back into place.
I'm not convinced this is a perfect solution long-term without mechanical connections on the TAPS switch, but time will tell. As of now, the handle is rock-solid and the new TAPS switch works perfectly!
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