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Rally 200 USA Femsa
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UTC quote
i have a 1975 USA ralley 200. next to the right hand grip there is a switch block for turn signals and kill switch. i would like to restore the kill switch which is missing but have no idea what the components look like to replicate. i have attached a photo of my switch and would greatly appreciate someone who has a complete switch posting photos of the components so i could see what needs to be replicated.

thank you so much, Pasman
Kill Switch
Kill Switch
@greasy125 avatar
UTC

Sergeant at Arms
Weird 80's Vespas & Cool Vintage Lambrettas
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Sergeant at Arms
@greasy125 avatar
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I would buy a new switch...

https://www.sip-scootershop.com/en/product/light-switch_60091000?q=Horn

if you're dead set on it being OG, then you could probably find a used one or one that's thrashed and use two to make one. if that's the course you're looking to take let me know and I'll root around and see if I have any spare bits from broken ones.
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Rally 200 USA Femsa
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thanks for responding greasy125,
i probably should have posted a picture of the cover as well so here it is. i've searched before but have never found anyone selling the correct switch. they all have buttons for things the wires don't support. so yes, when you have time to check and see if you have any parts for this type of switch it would be appreciated.
kill switch cover
kill switch cover
@socalguy avatar
UTC

bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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bodgemaster
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The 70's US switches are getting hard to find.

Here ya go … got one on Brownie.
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
@greasy125 avatar
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Sergeant at Arms
Weird 80's Vespas & Cool Vintage Lambrettas
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UTC quote
ah, I didn't realize it was *that* switch.

yeah, tough to find. I might have some bits of one floating around. I'll have a look.
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Rally 200 USA Femsa
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UTC quote
thank you SoCalGuy excellent picture.

geasy125 i'll check back regularly incase you come up with something.
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hey SoCalGuy,
your picture was great but could i trouble you for more detail?

the red arrow, is that just a washer on the I pin to support the spring?

the yellow arrow, the brass piece that the end of the I pin is in contact with...i'm assuming there's a hole in the brass piece that the pin can move through...correct?

i'm aware that when you move the lever to the left the spring moves the brass piece to the left where it contacts the brass square with the screw in it.

thanks again
Forum member supplied image with no explanatory text
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UTC

Style Maven
'74 50s x3 '87 PK125XL '92 PK50XLS Plurimatic - & - '58 AllState '68 Sprint '66(?) Super125 and '72 DanMotor Super150
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UTC quote
I had a '76 Rally w/ this DOT mandated switch on it which I gave to my son, w/ thumb lever busted off in the run position & we just use the key. It may still have those other bits inside if you can come up w/ the lever. Let me know if that would help but it may be a little while before I can find out.
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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bodgemaster
@socalguy avatar
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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UTC quote
Pasman, answer to both your questions is yes.

It's quite possibly the most over-engineered kill switch ever put on a motorcycle.

My original one disintegrated. I JB Welded & soldered it back together minus the spring. It actually works, but in reverse. I was saving it for spare parts. Let me know if you want it.
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
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UTC quote
wow! SoCalGuy, that would be very generous of you. if you would be willing to let it go i'd be happy to put it to god use.

very greatful, Pasman
⬆️    About 1 month elapsed    ⬇️
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UTC quote
thanks to SoCalGuy i was able to restore kill switch!! damn! won't let me attach video.
new kill switch
new kill switch
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UTC

Molto Verboso
ET3 & PX150 & GTS 300 Super Sport MY23 & Yamaha Neo's electric
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Molto Verboso
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ET3 & PX150 & GTS 300 Super Sport MY23 & Yamaha Neo's electric
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UTC quote
Could you post another picture of the switch in the OFF position?
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is this ok
Forum member supplied image with no explanatory text
@sdjohn avatar
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Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
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Veni, Vidi, Posti
@sdjohn avatar
'15 GTS300, '86 PX125EFL, '66 VBB, '01 ET4
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UTC quote
isn't that circlip gonna fall out? it's looking too big
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Rally 200 USA Femsa
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UTC quote
yes... i didn't have any of the oringinal components and was temporarily using the the only c clip i had while i engineered replacement components. i will replace the c clip with the appropriate c clip.
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