I have a '76 900SS and am trying to remove the left-hand switchgear so as to have access to the choke lever assembly which had been broken before I bought the bike. I have removed two long cap screws from the bottom of the switchgear, but what appears to me to be a top and bottom half of the switchgear box don't want to separate. I've removed the grip and would simply slide the switchgear down the bar but the switchgear appears to have a slightly smaller ID than the handlebar, perhaps resting in a notch. I expect if I break the switchgear trying to take it off it will be irreplaceable, and I have in my lifetime already broken too many decades old plastic bits on old motorcycles. Any help will be appreciated.
There is a peg on one half of the switch which locates into a hole in the bar if you fully remove the screws you might be able to separate the halves enough to slide it off but the 2 halves are held together by the choke assembly which is held on with 2 small screws which have to be removed.
Thank you Derek, I had found two cap screws on one side of the switchgear, and after walking away for awhile I came back with a fresh perspective and found a third cap screw who's removal allowed me to separate the two halves of the switchgear. I id find the two screws you mentioned holding the choke adjustment lever from rotating. I knew something was amiss there because I could see a crack in the plastic before I even started this repair process. As it first turned out the screws pass through molded bosses that provide a certain amount of space. Both bosses were fractured and as I took the choke mechanism off the bosses fell away. As I looked at the choke assembly and tried to figure out how it holds tension against the cable which wants to draw the choke lever back to the off position, I realized that there is meant to be two collars 180 degrees apart around the center hole that straddles the clip-on bar that provide friction. One entire collar was gone. It must have been gone a long time as there were no shards of plastic from the missing collar, only a jagged surface on the plastic gave evidence that it even existed. I've ordered a replacement assembly. Thanks again for your reply. My next search/plea for help will be to address the backfire I am hearing at idle, made worse for my neighbors from extra decibels given the bike's Termignoni exhaust. Best regards, Jim
Glad to help Jim. It's 14 years since I had a 900ss so my memory is a little sketchy but I seem to have pointed you direction though. Good luck with the carb issue.
