So something fell on the indicator lever and it broke off flush with the housing. Using glue didn't work, so i looked into different ways of fixing. Got myself a cheap complete switch-box from a late 90s Monster. I was aware that there are different connectors, but a bit of soldering to switch the wiring I would have been fine with. That will be the next option if my makeshift solution won't last. "Why would you not just buy a used original part?" They become harder to find. Also: Those prices. As an example, there is one WITH THE EXACT SAME SNAPPED OFF LEVER ON EBAY FOR 120 EUROS. Note: The lever inside the (newer) Monster-bit I needed is made of metal, but the dimensions are different so it won't fit into the older version. The old version is made of fiber reinforced plastic. So I found an STL-File on thingiverse for the part I needed: https://www.thingiverse.com/thing:5340653 Printed with red PETG worked ok, but due to the complex structure of the part, I didn't want to use it. So I cut off the tip. A look into the housing with the new tip attached. The original part was sanded down to take the tip of the printed lever and is held in place by a screw. the metal brace keeps the tip from turning on the lever. On the lower side you can see that the print isn't perfect. This is due to me probably not setting the support for the print correctly. The top side of the print looks ok and the functionality of the lever is ok, it makes the desired clicky noises. Will be tested thoroughly when it's back on the bike.
Well done Now you want to work on finishing. Reprint the part and experiment with wet and dry paper. For the shiny finish build yourself a vapour bath. That is a jar with sealed lid and cotton wool in the bottom. Make a rig so the part can be suspended in mid air. Soak cotton wool in acetone. Seal it all up and wait. Keep checking until desired shine is achieved. Remove part, but do not touch it. Allow to harden and the shine develop. Result, nice shiny plastic part via acetone smoothing.
Hi, try this link taken from a forum in the US. https://www.shapeways.com/product/Z...ature-for-switch-036138454?optionId=119029287
Thank you for the detailed instruction! I hope I will find the time to try it out (The defect occured some time in March and I got around to put the housing together yesterday. *sigh*). Just checked out what it would cost to have it shipped to me. That'd be 35€, half of it p&p. I don't think that's an unreasonable price, if the part ist good. If I ever find the time, I will try to make a steel lever like the one pictured, which is for a Monster. It has a more simple structure than the plastic part: 1.6mm steel, two bends, a long hole and two studs which seem to be press fit. Doesn't seem to be heat-treated, just painted.
So after going for 1/2 hour drive, I know three things: - The indicator fix works - The valve stem seals are gone, as it took ten minutes of driving for the smoke to disappear from both exhausts - The MOT-equivalent check was due in August.
