replacing choke switch

[Toad face killah]

My wifes 550 rmk got its choke switch broke off. I got the replacement pieces from my polaris dealer but cant get the unit apart without feeling like im going to break it. I unscrewed the unit so its separate from the dash. It appears to be 3 parts. Is there a trick so to get it apart so I can replace the innards?

 

[volcano buster]

Yep

 

[Toad face killah]

Thanks for the sarcastic remark volcano buster. Anyone else have some tips?

 

[volcano buster]

Well, what actually broke?

I have broken some but the part just inside the housing was still intact. All that I have needed to do was replace the roll pin and the outer lever. It isn't that hard, but I used a small metal pick to pull the portion up so that I could work on it.

 

[427cobra]

I never figured out the trick... Ended up breaking the housing trying to get it apart. Found a new one on eBay for $30.00.

Its like the junction box was glued together. Maybe some heat would help...??

 

[whoisthatguy]

It's been awhile, but I thought that you had to pull the plunger back out before being able to wedge the lever back on. And then, I may be completely wrong.

 

[skibreeze]

IIRC mine had some glue holding it together.

 

[Goinboardin]

It's been awhile, but I thought that you had to pull the plunger back out before being able to wedge the lever back on. And then, I may be completely wrong.

That is right. In order for the hole in the lever and the hole in the pull rod to line up for the roll pin to slide into place you have to pull the pull rod/plunger out, hold in place, position the lever and slide the roll pin in place.

I had no idea you could take them apart more than lever removal. Learn something everyday.

 

[Hardass]

You will notice a seem around the end of the housing usually if you take a pocket knife and stick it on that seem it will seperate there is a small amount of glue so press firmly the rest you will figure out when you get it open i have done lots of them.

 

[oscar680]

X2^

use heat if the glue is really stubborn