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  • #1

    High / Low Beam Switch

    Hi,
    At a time longer ago than I care to think about, my high/low beam switch broke off. It seems others have also had this problem.

    http://www.xs11.com/forum/showthread...gh+beam+switch
    http://www.xs11.com/forum/showthread...gh+beam+switch
    http://www.xs11.com/forum/showthread...gh+beam+switch

    I could and may get an entire replacement handle bar electrical control assembly for $51.00 at Mike's XS or maybe a used unit for less. But I always like a challenge, so I'm wondering if I can machine one. I know some molded parts are impractical to machine.

    My request here is for a picture of that little part inside the switch which breaks. It's going to be a while until I can get back with my bike, but I'd like to get my wheels churning on this (no pun intended).

    Thanks,
    Kevin

    '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
    '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!
    Tags: None
  • #2
    I'll see if I can take a photo and send it to you. The part is plastic, and has metal that fits on it for the contacts. The part that breaks is usually the plastic part that the black thumb rest screws on. The plastic is VERY BRITTLE after all these years, and the kill switch suffers from the same problem. As ALL the parts will fit from other models, using the XS650 assembly for parts seems to work well. On the Specials, they are an almost exact replacement, with just the connectors needing to be changed.
    Ray Matteis
    KE6NHG
    XS1100 E '78 (winter project)
    XS1100 SF Bob Jones worked on it!

    Comment

    • #3
      I broke one once trying to pry off the grip. Be careful doing that!
      Skids (Sid Hansen)

      Down to one 1978 E. Stock air box with K&N filter, 81H pipes and carbs, 8500 feet elevation.

      Comment

      • #4
        Thanks, that would be great. But like skids said, be careful. I don't want you breaking one that is functioning just to get a picture for me. It's find if you start out with one from your parts box that already has the tab broken off.
        '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
        '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!

        Comment

        • #5
          I just went through mine...

          And had to fix the same thing... I removed all the electrical contacts and put both pieces in my ultrasonic cleaner (definitely worth the small investment from Harbor Freight...) and actually used superglue to repair it before putting it all back together... Mine was a pretty clean break, so there was really good contact. I don't know how long it'll hold up, but I gave it a pretty brisk switching and it seemed pretty sturdy. I also know of a guy on here who posted a thread about replacing the switch assembly with one from an R6 (super readily available for about $20 in good shape) and has a good picture of how all the wires hook up... I'll try to find the link he posted...
          81 XS11

          Comment

          • #6
            The link in question

            http://www.xs11.com/forum/showthread...t=left+control

            It goes without saying that if you want the bike to be stock, this isn't for you, but I'm doing mine cafe style anyhow and so this idea is my next stop if/when that piece breaks again...
            81 XS11

            Comment

            • #7
              I second the idea to get one from MikesXS and use the internals to repair your switch. Did that on my 80SG when the hi/lo beam switch cracked internally. Then you have more part for other stuff down the road in most cases.
              Howard

              ZRX1200

              BTW, ZRX carbs have the same spacing as the XS11... http://www.xs11.com/forum/showthread.php?t=35462

              Comment

              • #8
                Thanks for the link to the R6 control. I do like the lower cost of the replacement, and the fact that it's newer parts.

                I get that if I value my time, I would just get the Mike's XS control, install it or swap the parts I need, and move on. But it irks me that so many people have to get the whole control or do a retrofit to get their hi/lo functionality back. I was just trying to see if it was feasible for me to make the part and fix what's broken. Ya know, if it ain't broke, don't fix it. If/when I do this, I'd probably make a couple dozen to hand out. Just searching for a bit of info so I can contemplate it and work out the details until I get a chance to go visit my bike in storage..............
                '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
                '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!

                Comment

                • #9
                  A Bit of Info

                  Originally posted by CRXSi90 View Post
                  Thanks for the link to the R6 control. I do like the lower cost of the replacement, and the fact that it's newer parts.

                  I get that if I value my time, I would just get the Mike's XS control, install it or swap the parts I need, and move on. But it irks me that so many people have to get the whole control or do a retrofit to get their hi/lo functionality back. I was just trying to see if it was feasible for me to make the part and fix what's broken. Ya know, if it ain't broke, don't fix it. If/when I do this, I'd probably make a couple dozen to hand out. Just searching for a bit of info so I can contemplate it and work out the details until I get a chance to go visit my bike in storage..............
                  Here Ya Go !!!





















                  If Ya need any more LMK HTH
                  1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
                  1979 XS1100SF (stock-euro mods planned)
                  1984 XV700L Virago (to be hot-modded)
                  1983 XJ750MK Midnight Maxim (semi-restored DD)
                  1977 XS650D ( patiently awaiting resto)

                  Sometimes it takes a whole tank of gas before you can think straight.

                  Comment

                  • #10
                    More Pics

                    Thought Ya might need these also.











                    The screw hole is a #36 bit size or in between 3/32" and 7/64"
                    1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
                    1979 XS1100SF (stock-euro mods planned)
                    1984 XV700L Virago (to be hot-modded)
                    1983 XJ750MK Midnight Maxim (semi-restored DD)
                    1977 XS650D ( patiently awaiting resto)

                    Sometimes it takes a whole tank of gas before you can think straight.

                    Comment

                    • #11
                      That's fantastic! A couple questions...

                      Is the pocket where the 2- and 3- point contacts sit rectangular with sharp corners? That would be difficult to make with a conventional rotating cutter, but maybe it could work by notching out the corner or modifying the copper contacts.

                      Is the ball pressed into place, or is it floating?
                      '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
                      '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!

                      Comment

                      • #12
                        Originally posted by CRXSi90 View Post
                        That's fantastic! A couple questions...

                        Is the pocket where the 2- and 3- point contacts sit rectangular with sharp corners? That would be difficult to make with a conventional rotating cutter, but maybe it could work by notching out the corner or modifying the copper contacts.

                        Is the ball pressed into place, or is it floating?
                        Yes, square corners on the recesses.
                        The ball floats in a tapered hole which is a #7 drill bit size, on the contact side, to a #14 on the ball side which retains the ball, which is drilled thru.
                        The small recess is drilled with the #7 bit size also BUT not all the way thru, as can be deducted from the measurements given.
                        Some pics:



















































                        Last edited by Schming; 01-13-2013, 01:44 PM. Reason: add info
                        1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
                        1979 XS1100SF (stock-euro mods planned)
                        1984 XV700L Virago (to be hot-modded)
                        1983 XJ750MK Midnight Maxim (semi-restored DD)
                        1977 XS650D ( patiently awaiting resto)

                        Sometimes it takes a whole tank of gas before you can think straight.

                        Comment

                        • #13
                          Thanks, I took a first pass at putting together a CAD model/drawing. I have to go back and review some of the pictures and think through their design intent because I know there are details I haven't captured correctly. I'll try to post a screen shot when I can get into my photobucket account.

                          Kevin
                          '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
                          '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!

                          Comment

                          • #14
                            Sounds good Kevin, if I can be of assistance, LMK

                            I apologize for the blurry pics, if ya need any clearer LMK.
                            1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors )
                            1979 XS1100SF (stock-euro mods planned)
                            1984 XV700L Virago (to be hot-modded)
                            1983 XJ750MK Midnight Maxim (semi-restored DD)
                            1977 XS650D ( patiently awaiting resto)

                            Sometimes it takes a whole tank of gas before you can think straight.

                            Comment

                            • #15
                              preliminary CAD work...

                              I'll probably want you to review this at some point to see if I didn't accurately represent anything, but I can probably take it a little bit further.
                              '81 XS11H Venturer - holed up in storage while life happened since 07/08/04
                              '81 Kawasaki KE175 enduro - 63 mph of smokey fun, now with collector plates!

                              Comment

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