TY175: Throttle Body / Kill Switch

So I settled on the TY250 style of switch gear withe the kill switch incorporated into the throttle body, rather than the separate kill switch (see here).

This is what I started with:

This is it stripped and cleaned:

And finally back together again:

TY175: Levers and Throttle - Update

Following on from the previous post on levers and throttle, I've finally got a replacement perch for the damaged one (Thanks Tom).

So, I now have a complete set of controls.....

.... except I don't. I'd been think about how or what was used originally for the horn and kill switch. I believe the switch above is TY175, but have realised that the TY250 has the same switch, but incorporating a horn button. So, I have this to refurbish and use instead:

As for the engine kill button - it seems I'll also need a TY250 part. Found (but not bought) this throttle with kill switch on eBay ($200 !):

It looks a neater solution than the seperate 'afterthought' kill switch. Mine shown below

And a different TY250 option below.

I'll see what comes my way first.

TY175: Rear Mudguard

This was a bit of a battle. I started with a new pattern rear guard, a NOS Yamaha inner metal guard, and all brand new Yamaha NOS fixings, grommets, etc.

So I offerd it all up, and with a lot of pushing, pulling and swearing, I managed to get all the fixings in, but, the mudguard was kinked, and under a lot of stress.... So, scratch head, and back to workbench.

As the inner guard was genuine Yamaha, I figured that would be the best alignment of the mounting holes. But, against my frame, the rear hole needed a little elongation to fit. You can just see it below.

I then had to elongate the three holes in the plastic guard to match the 3 mounts on the inner guard. Once this was done, it all mounted up OK. I had to add a washer to the rearmost mount, on the visible top of the plastic guard to hide the elongated hole, but it's not noticeable.

Below are some general shots of where the build is at.

TY175: Rear Light

I bought a pattern rear light from eBay, thinking that was a clever move. It turned out to be OK quality but not the same as the original Yamaha part. See below, the extra mounting hole at the rear of the new light on the left.....

So, I refurbished the existing light on the right. The only part used from the pattern light was the chrome strip, as the original one is scratched, and dented.

The original light cleaned up OK, I used some new grey cable sheathing, and added new terminals. It turned out pretty well, certainly far better than the pattern one.

TY175: Catch Up & Switch Completed

So, I have been busy on the bike, but I haven't fopund time to keeo this site up to date, so the following may be a little random!
First up - I completed the switch gear.
As it was originally:

See earlier posts (No 1) & (No 2) for clean up of the internals.
Then, using some black and red Humbrol model paint from eBay, along with some sheathing from the XS 650 Shop in Germany and a kit of electrical connectors from Yambits, and I ended up with this:

NVT - Riders Handbook - Wiring Diagram

Here's a scan of the wiring Diagram for the NVT Rambler 125.

TY175: Swith Gear - Update

IThis is where I got to last time, refurbishing my switch gear.

I found a cheap unit on eBay that had the opposite switch broken to mine, so, below, I've incorporated the good bits into one decent switch.

Here's the 2 units side by side. My good one on the left, and the newly purchased one on the right.

I've ordered some new silver cable sheathing from www.xs650shop.de, and I've some red and black Humbrol paint coming from eBay to paint in the letters and red sqaure. I'll update when I do these bits.
I'll also do a final clean up on the 2 black plastice knobs, to get rid of a bit of the scratching, and clean between the ribs a little more!

TY175: Swith Gear

Stripped down the switch gear, cleaned and polished each part. I need to make a new 'post' for the broken one. I seem to remember reading an article about making a new one by forming a mold of a good one, and using some pourable plastic resin material to produce a new post. I'll have to look it up.

I also need some new grey wiring loom tubing for the cables. Anyone reccomend a good place to get it? I've temporarily reassembled the switch to stop me losing any small bits, and so I don't forget how it goes together!

 

what I statred with

not too grubby inside

completely stripped down.

polished and component parts

the right hand clear plastic part is the one that need a new 'post'

polished and back in one piece - temporarily anyway.

Can anyone upload a link to the post that showed someone making a swith 'post' please? I think it involved a plastercine mold of some sort.

Also, what red & black paint does anyone suggest for painting the letters & red square back in please? A small pot of Humbrol or similar??

Finally, where do you reccomend I get the cable sheath from, and is heat shrink preferred?