Forum

[StogieRob]

Greetings, All!
I've finally received all of my miscellaneous parts for the light switch in the casquette, the new lockset, and the new clutch/brake handles and mounts.  I love ordering and guessing while waiting weeks to find out what i screwed up...
for the relatively easy one - how do I remove the rubber grips on both side of the bike?  I'll be putting them back on, but they are in the way of replacing the clutch and front brake mounting bracket.  All i have is a small hole in the end of the rubber grip.
The lockset - wrong type of gas cap and the lock cylinder on the new cap does not match the cylinder size on the old cap.  Also, though easier to resolve is that the plastic wiring plug on the end of the ignition wires does not match what is on the bike.  I'll probably take the lock to a locksmith and get my installed one rekeyed to match my new keys.  i'm moving the ignition so i'll be shortening the wires, so the mismatched plug is less of an issue.  OK, i'm not really asking for help on this one, just bitching...
Now the help - i removed the ignition and the mounting ring from the casquette.  the new light switch is slightly smaller in diameter than the opening in the casquette.  Here's where I need ideas.  How might I make a metal gasket or sleeve to solidly mount the new lightswitch into the opening?  I only need a sleeve that would be no deeper than 1/4" and to fill about 1/8" of the opening to get a good pressure fitting for the light switch...
Here's a pict of the bottom of the light switch - 

Thanks!
StogieRob

[Wheaters]

I'd try putting a finger over the hole in one grip and stick an air line nozzle in the other. Pump up the grips with low pressure air to lift them off the handlebars and break the seal. If it doesn't lift them completely free, squirt some WD-40 or similar under the loosened part and try again.

Having said all that, it's probably to write them off and buy new grips then cut the old ones off with a sharp knife!

[Adrian]

Can you not simply unbolt the brake and clutch lever perches from the handlebar? The switch gear clusters on both sides just unscrew as well (2 x 5mm screws on each), which will let you remove the r/h grip as part of the throttle. Try a hot air gun to warm up the left hand grip.



I don't know where you bought your old-style light switch from, mine came with a rubber sleeve included. Maybe a slice of bicycle inner-tube?



A.

[Mark M]

The rubber ring for the switch (also fits ammeter) is available from our Hosts part number 140248.

REgards, Mark

[RoSy]

If you get a bicycle spoke or similar rod and insert it between grip and bar push it in to the end of the grip, then with your WD fine tube spray push that in along side the spoke then squirt a few times, the WD soon spreads around and the grip will slide off easy.

[stinkwheel]

Before getting your lockset re-keyed. Make sure the locks work properly. I am the proud owner of a pair of Indian made toolbox locks that work backwards. You can only take the key out in with them in the "open" position and extensive fettling has shown they were made like that and cannot be fixed. You can actually re-arrange the wafers in bullet locks yourself surprisingly easily to take whatever key you want, most of them only have 3 active wafers anyway. Search online for re-keying locks.