Neutral Switch - failed - Ducati.ms - The Ultimate Ducati Forum
 
LinkBack Thread Tools Display Modes
post #1 of 2 (permalink) Old Dec 23rd, 2018, 3:57 pm Thread Starter
Lifetime Premium
 
grimah1w's Avatar
 
Join Date: Jun 2006
Location: Woodlawn, TN, USA
Posts: 682
Garage
Images: 3
Neutral Switch - failed

I've had my '02 ST4s since May 2002. Recently I noticed the common issue of intermittent neutral light. While doing some winter time maintenance and installing a MOSFET VRR and volt meter, I decided to check the switch and check full the path for connectivity etc. Checked the usual suspects first: bulb, bulb holder, big connector on the left hand side, the switch AMP connector, and the connector at the switch. All had good connectivity so I pulled the switch. No spring effect to the plunger and it was severely worn after about 26K miles. Replaced with PN 539.1.021.1A and now functions as designed.

Photo of worn switch:


Photo of side by side old and new switch...little blurry, sorry.


I was surprised by the wear on the switch plunger. I believe that the spring failed internally as well. May dissect the switch to confirm. No exterior corrosion.
Attached Thumbnails
Click image for larger version

Name:	2018-12-22 13.13.22.jpg
Views:	147
Size:	50.0 KB
ID:	933981   Click image for larger version

Name:	2018-12-22 09.36.17.jpg
Views:	137
Size:	54.0 KB
ID:	933983  


Vinnie R.
Tennessee

2004 998s FE
2002 ST4s
grimah1w is offline  
Sponsored Links
Advertisement
 
post #2 of 2 (permalink) Old Dec 27th, 2018, 12:55 pm Thread Starter
Lifetime Premium
 
grimah1w's Avatar
 
Join Date: Jun 2006
Location: Woodlawn, TN, USA
Posts: 682
Garage
Images: 3
cut view

So I did cut the neutral "switch" open to view the internals. Used a angle grinder so precision was a little lacking but I did my best to not damage the internals.

The tip that extends into the gearbox had been worn down, shown above in previous post. Not exactly sure of what it contacts inside the gearbox to connect to ground when in neutral.
The plunger, at left end of the photo, rides inside a plastic sleeve that extends the length of the "switch" and provides a simple path from plunger through the spring to the external barrel connector (right end in photo); very simple arrangement. The plunger, spring and connector are completely insulated from the metal threaded housing.




PS Moderators, if possible, can you move these to posts into https://www.ducati.ms/forums/40-spor...scratcher.html ?
When I started this thread, I had searched Neutral and switch using the site's advance search in Sport Touring and never came across result above... until I tried Google. Anyway, if you can move these two posts to the end of that thread to combine them it would be nice. Thanks!
Attached Thumbnails
Click image for larger version

Name:	neutral-switch-cut-view-2018-12-27.jpg
Views:	93
Size:	59.8 KB
ID:	934113  


Vinnie R.
Tennessee

2004 998s FE
2002 ST4s
grimah1w is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ducati.ms - The Ultimate Ducati Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Neutral Light Switch Fault - Hypermotard 1100 Evo SP notoriousrab430 HyperMotard 4 Dec 14th, 2018 7:28 pm
Neutral Switch - No Light Issue CinKo Superbikes 5 Jul 5th, 2018 7:24 am
Neutral switch is too short mondoitalia Superbikes 2 Feb 11th, 2017 1:41 am
Clutch neutral switch turf21 HyperMotard 3 Jun 23rd, 2016 12:29 pm
1996 900SS Steering & Neutral Switch Questions nomadwarmachine Supersport 4 Mar 8th, 2016 8:36 am

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome