Don't know if this is very common but I lost my green starter button a couple of months back. The green centre was still there as well as the spring . It appears that the green rubbery outer weather proof button is normally glued to the rigid plastic centre. This had given way and my little green button was lost on the road somewhere between my last stop and home - about 2 klm. I spent 3hrs walking the road and back to try and find it but to no avail.  


I did look online but at the time there was one or two second hand assemblies available in Oz but they looked pretty ratty.

Eventually came across a very easy workaround. I found that the black rubber plunger from a 10ml syringe fitted snuggly over the red kill switch stub. Had to remove the spring as it was too long and just pushed the new button off. It worked fine so I applied a couple of thin smears of contact adheasive to the green centre button shaft and the inside of the new black button cover.

Its been there for over a month now and I've given it a tug and it seems to be fairly secure. The black plunger rubber had a slight conical tip which I smoothed down with some wet & dry paper.

Hi Kaptain,

A common problem indeed,
https://www.k100-forum.com/t1430-starter-button-busted

But your solution looks great.

Thanks for posting.

dee why

ingenius , who'da thought. glad to see you removed the sharp prongy thing . well done . hope it continues to work.

great solution ...have fun !

Still Working?

It was a great short term solution for 12 months but I found that without the spring to retract the contactor the contacts would jiggle around and more often than not they would make contact. At that time the idle was quite high but would settle down if I pulled the button out. I was also having a few issues with my starter relay and went thru 2 units. I suspected that the starter button issue was the cause of these problems. I've since installed a fabricated button, courtesy of one of our generous members, and have had no issues like this since.

The pattern for the button is somewhere here on our forum and there are instructions for removing and cleaning the starter/kill switch assembly. Try the search box on the Portal page.
Cheers.

There is a guy in Alicante - Spain who produce green ignition button replica. Price is 8 Euro plus shipping. Site is in spanish but you can contact him by mail, in english.
I bought speedometer gears from him. Fast and kind. Here is a link: http://www.hardtoptire.com/producto-hardtop.php?id=178&id_familia=105&id_catalogo=19

Regards

Hey Nino!

Would be nice to have a adrress or link

Cheers

Chocolate wrote:Hey Nino!

Would be nice to have a adrress or link

Cheers

Look again

Yeeeep :-)

I have been using the syringe plunger solution for over a year now and generally have had success. While it is a good solution at the time, I was always hoping for a permanent solution. 

Thanks for replying with the link Nino

Sunny

Would anyone be interested if I buy some.

In australia

Sunnyk75 wrote:I have been using the syringe plunger solution for over a year now and generally have had success. While it is a good solution at the time, I was always hoping for a permanent solution. 

Thanks for replying with the link Nino

Sunny

Here is a link http://www.hardtoptire.com/familia-hardtop.php?id_familia=105&id_catalogo=19

Site is in spanish, but you can send a message in english on info@hardtoptire.com. The owner will answer in english

Regards

nino wrote:Here is a link http://www.hardtoptire.com/familia-hardtop.php?id_familia=105&id_catalogo=19
Site is in spanish, but you can send a message in english on info@hardtoptire.com. The owner will answer in english

The page can be translated into English by clicking on the Union Jack in the upper right corner.

I could not work up the appetite for the $200 OEM solution. Not even for the much more reasonable Spanish one mentioned - I think that's 8 Euro


So, reducing the problem to its main components: the top of the green "mushroom" has parted company with the stem of the mushroom - I need a mushroom with an 18mm long stem and the stem needs to have a diameter that goes from 5mm at the top to 2.5mm and then 3mm as indicated below. Inside the hole through the red thingy there is a narrowing that, with the narrowing of the stem, restricts movement, stops the button from popping out and stops it from going too far down. Plus I need a spring of course.








Fortunately Eureka, in the process of making pop rivets, inadvertently provides such a mushroom.



In the image below you will notice the red thingy and the original metal pin that is pressed into the original green thingy which broke. You will also notice among other stuff a Eureka pop rivet head which will be the donor part for the mushroom - the diameter and head are perfect - it has to be shortened a bit.



You will also notice that some blacksmithing has been done; hammer flat the pin above where the manufacturer thickened the pin to keep the rivet head and pin together. The ID of the rivet head is too big to press fit the original pin.








Assemble the red thingy, scavenged spring, mushroom and rivet pin. Press fit. If pressed in too far - tap the other end so it's not pressed in too far - adjust - until it operates properly


Cut off the excess pin and turn a suitable rubber cap on the lathe. Pity it's not green like the OEM part, but I can live with black instead of green. Once fitted in the handle bar control I'll stick the rubber cap on with contact adhesive






Rubber cap attached

[size=16]
[/size]

Pressed in (that's a washer in the vice - too few hands to hold, press in and take photo)






Released

Brilliant - absolutely brilliant!

I just repaired mine. Steps included drilling a small hole in the green stalk and finding a suitable self tapping screw. The screw is placed through a small washer and the spring and screwed into the hole of the green stalk. A suitable cover is then siliconed on top.
I was slack and attacked this without removing anything from the bike. This system has worked on my basic K100 for the past 13 years and is now on my 87 RT.

Holister wrote:Don't know if this is very common but I lost my green starter button a couple of months back. The green centre was still there as well as the spring . It appears that the green rubbery outer weather proof button is normally glued to the rigid plastic centre. This had given way and my little green button was lost on the road somewhere between my last stop and home - about 2 klm. I spent 3hrs walking the road and back to try and find it but to no avail.  


I did look online but at the time there was one or two second hand assemblies available in Oz but they looked pretty ratty.

Eventually came across a very easy workaround. I found that the black rubber plunger from a 10ml syringe fitted snuggly over the red kill switch stub. Had to remove the spring as it was too long and just pushed the new button off. It worked fine so I applied a couple of thin smears of contact adheasive to the green centre button shaft and the inside of the new black button cover.

Its been there for over a month now and I've given it a tug and it seems to be fairly secure. The black plunger rubber had a slight conical tip which I smoothed down with some wet & dry paper.

This is exactly why I'm in this group. The genius solutions that others have come up with before me will save me SO much time. Thank you for this. I know this is an old post, but hopefully my resurrecting it will help others find it also. I'm in Nicaragua where I can't get parts but I can get syringes.,