Ignition barrel shear bolts and solder help
 

Have a funny one here, my mate has an 02 Triumph TT600 (no accounting for taste) with an ignition problem.

Turns out that there was a problem with the wiring coming out of the bottom of the ignition barrel, a bad connection.

The first problem is that the ignition barrel is held in with shear bolts, just after some ideas for getting them undone, I'm thinking take the top yoke off and try to weld a short bolt to the end of the stumps that have been left as I cannot get any mole grips on there.

http://i76.photobucket.com/albums/j1..._/IMAG0032.jpg


Next problem is my mate took the bottom of the barrel off and we could see that one of the wires had shorted and blown out of the board it is connected to, this is what the key turns against

http://i76.photobucket.com/albums/j1..._/IMAG0038.jpg

I tried to solder it back in the little cup for him but the solder wouldn't stick.

Apart from a replacement barrel do you have any ideas? There is currently only one on eBay, a full lock set for £90.


Cheers mighty org

Re: Ignition barrel shear bolts and solder help
 

If you want a bodge solution you could put a screw in the hole and then solder the wire to that.

It works for telephone lines (although I'll deny it if asked by my boss)

Re: Ignition barrel shear bolts and solder help
 

Sure. Good one.

Re: Ignition barrel shear bolts and solder help
 

I've taken out what I believe to be the same as those bolts on my Daytona. I dremmeled a nice fat slot in the middle (with a tiny amount of probably unnecessary damage to the yoke) and was lucky with a screwdriver. Failint that, just last night I drilled out some shear bolts for a fireblade. Slowly slowly catchy monkey.

I have no idea about the ignition though I'm afraid.

Re: Ignition barrel shear bolts and solder help
 

you prob need to clean the dirt off that contact to solder it back on. maybe small file?

Re: Ignition barrel shear bolts and solder help
 

Good morning all.


Drill the head off the shear bolts. Be careful not to drill into the switch body. The switch can then be removed, leaving a nice length of bolt sticking out of the yoke to get the grips onto.
Most ignition switch retaining bolts are 8mm. So drill say a 3mm pilot hole to just below the level of the switch body, (get it central), & then use an 8mm drill bit, you'll find that the head of the bolt will shear off before you have drilled too far into it.

As for soldering. A good flux helps. I still use Baker's fluid. It's difficult to find, but is the dogs when trying to solder manky connectors.


Cheers.

Re: Ignition barrel shear bolts and solder help
 

Cheers guys.

I've tried cleaning it up with a tiny file after the pic was taken, I think the crap around the edge is the melted plastic sleeve from the wire.

How do you use the flux? I tried to get some in the cup itself put the wire in the cup and then introduce the iron and the solder to it. Does that sound right? Or should I try another approach?

Cheers

Re: Ignition barrel shear bolts and solder help
 

That sounds right. Flux and tin the wire and then carry on as you've suggested introcucing the heat from the other side if you can so it'll draw the solder in.

Re: Ignition barrel shear bolts and solder help
 

Cheers dude, will have another go