Aprilia SR50 Brake Switch Boot

thingiverse

PART DESCRIPTION: Rubber boot for brake lever electrical switches. If you have searched parts breakdowns, you will find these boots are not listed. These fit my 2006 Aprilia SR50 Factory Ditech scooter; however, I think the brake light switch is common across many models including motorcycles, so it may be more universal than just the SR50. PRINTING TIPS: I made this from Ninja Flex. Two shells and 10% infill created a stiff but somewhat flexible part. I also tried one shell, 10% infill, which was more flexible. Ninjaflex is disappointing in my opinion; it is flexible, but only sort of, especially as parts get smaller like this one. ASSEMBLY: I ended up using the one shell wall thickness part. I was barely able to push the spade connectors through the small end of the boot. The large end of the boot that fits over the switch fit very tight too; I would recommend scaling up the part, and it will help the fit on both ends. See notes below on various diameters of this part; I recommend measuring parts you have and determining how much to scale. The file provided is the exact same size as the original rubber boot; the ID of the large end of the boot is 10mm. The part shown in the picture is the "brass colored" part, and no scaling of the boot was done. It fit but was very tight; if I were to print another boot to replace this one, I would scale it bigger. * I still need to print one more boot yet to fit the plastic part; I'll scale the next one up and provide an update or new file depending on how it fits; I'm also going to try Makerbots flexible filament and see if it behaves any better. PART VERSIONS: The original brake light switch has been superseded by a new part number. I just ordered two new ones as both my switches were bad. I ordered the parts from Apriliasuperstore, and it appears they may have been cleaning up their inventory or didn't have two of the newer ones in stock or maybe there are a couple versions of "newer" ones; I don't really know. Both parts fit and worked fine. See the pictures; I posted a photo of the new parts I received - one is brass colored, and appears to be the same as the original switches, and then I also got a slightly bigger diameter plastic one. Here's the info from the website, but I really have no idea what the part numbers really mean: Old Part Number? AP8127305-55207 - AP8127305/580953 Superceded "new" part number: 642632 [Diameter is approx 11.6 mm] 2006 black painted parts that came on the SR50 [Diameter is approx 10.9 mm] brass colored part [Diameter is approx 12.0 mm] 2015 Plastic part Both parts I received are 580953, each package was different but had the same part number on it; the plastic part was dated 2015, so I would assume it is the "new" part; no date on the other package and it looked like an older package... How I Designed This Cubify Design CAD file I've provided the CAD file too. It is a Cubify Design file.