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Microswitch sticking will start, but stop as soon as foot off the red switch lever

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Replaced micro switch

Posted on Aug 20, 2008

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The DC04 Zorbster runs slow, it still picks up but I am worried it will overheat. If I hit it at the front, the motor picks up speed until the next time I start it up. Can you help???


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I had a problem with my switch not working. The cheesy microswitch has a little nub on the back that breaks off. They kind of work like a ball point pen. I noticed that if I held my thumb against the back of the microswitch, it would click on and off.

Disassembly:
First, unplug the machine and disassemble the switch housing. There is a screw in the front. It takes a no. 10 Torx driver to remove it.
On the back there appears to be two little tabs that need to be pulled out. Don't mess with them! They are there to fool you. Instead, with a flat tip screwdriver, reach down past the tabs and pry inward (the handle of the screwdriver moves outward, the tip prys inward).
On the front is a little tab that needs to be gently pryed down. The unit should slide out.
With your thumb against the back of the switch, press the button. If it seems to be staying down on one stroke and popping up on the next, continue reading. Otherwise, you may need a new switch.

Now for the fix/jury rig:
With the plastic housing set aside. Put all the wiring and switch in it's place on the vacuum. The switch has grooves that allow it to slide onto the vacuum. Everything should go in neatly.
What you need is a thin piece of wood or plastic, about 3/4" long and 1/2" wide (a popsicle stick would probably work). Slide it between the bottom of the switch and the molded plastic on the vacuum. Make sure it is snug. Try the switch. It should be working now.

Now carefully slide the housing back on. I like to depress the switch first. Make sure the housing snaps back on. It takes a bit of force, but it should slide fairly easily right up to near the vacuum's face. If not you may want to make sure you're not interferring with any wires etc.

Good luck,
bentod

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On/Off switch
http://www.greatvacs.com/Kirby%20Powerswitch.shtml


Hope that helps!

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