ProjectFiberglass

Project: Fixing Kill Switch on REV Skidoo

Submitted By: Mike Smith

Date: January 21, 2009

Last night Maffer and I tackled a common problem on the Bombardier REV platform sleds that have the push down Toggle Style kill switch on the handle bars (as opposed to the plunger style used on the older sleds, and now the newer sleds). The problem with this switch is that when the button is pressed to shut off the motor, it wouldn't shut down, you would need to wiggle the switch to shut down the sled. According to some of the online message boards the fix is relatively easy and doesn't necessarily require replacement of the switch, just a cleaning.

First we removed the Aftermarket hand guard on the throttle side and the x-package bar pad. Then we removed and disconnected the throttle lever, a Phillips head screw from the side cover of throttle block ( inside cover-towards the center of the machine) and one Phillips head screw on the bottom of the throttle block. Now you have some room to maneuver the throttle block to get the side cover out of the way to get at the 2 Philips head screws for the kill switch. With those removed the entire switch can be pried up with a flat top screw driver (gently) then unplug the wire connector.

When you unplug the wire connector be careful not to loose the triangle shaped copper contactor and spring. To fix the switch all you need to do is remove the black tarnish from the 3 bumps on the copper triangle contactor, and from the 2 round copper contacts on the wire connector for the kill switch. I gently used a very sharp utility knife to do this, but very fine sandpaper or a points file can also be used. Be careful not to remove too much material, you only need to clean the parts.

To reassemble, maneuver the throttle block so that you have the maximum length on the wire for the kill switch. Next, place a dab of dielectric grease on each end of the spring and reinstall in its groove on the kill switch. Next reinstall the copper triangle contactor on top of the spring, it can only be installed one way. I applied a thin coat of dielectric grease on the surface of the wire connector and the 2 round contacts to help prevent corrosion, and to help lubricate the moving parts of this switch. Now you have to gently plug in the wire connector being careful not to disturb the spring and triangle piece inside the kill switch. The dielectric grease on the spring helps hold everything in place while you reassemble. Next reinstall the rubber gasket, and push the kill switch back in place into the throttle block making sure its all the way in place, if not the screws will not line up.

The rest of the assembly is just reverse of the disassembly. Hope this works as well for you as it did for us. Next time I'll remember to take some pictures, but once you start at it the description above becomes clear!

Cheers, Mike