Sur-ron ignition replacement (no key needed)

thingiverse

This is a replacement ignition housing for the Sur-Ron electric bike. I had my ignition jam up, preventing me from turning it on. So, while waiting on a replacement, I decided to model one that uses some of the stock parts but replaces the need for having a key at all. This can be turned with a screwdriver or print the included key, which is removable, but will securely stay if pushed into place. Handy for people who have also had their ignition locks jam up or simply don't want the hassle of a key - I've had one ride where somebody forgot theirs after getting to the riding spot! Print with the 'top' facing down on the print bed with no support. This is printed as a single but movable item. The wall tolerance is 0.3mm vertically and 0.6mm horizontally, which should be plenty for any reasonably calibrated printer not to cause it to seize up. After printing, rotate the center piece around several times in both directions to smooth out any rough internal surfaces - it's okay if there's a little bit of resistance but it should rotate fairly freely. Assembling instructions are included as images above and in the download. Disassembly of your existing ignition is essentially the reverse of the above after removing the 2 hex bolts that hold the ignition housing cover in place, push the side tabs in, and wiggle the stock connector out. IMPORTANT: There are no movement limits with this design, so take care not to rotate it beyond one click after installing - though I have tested rotating it around several times without causing any shorts or damage. Also, I've offset the 'on' and 'off' positions. With the stock bike, having the key slot straight vertical was 'off' and slightly to the right was 'on.' With this design, slightly to the left/counter-clockwise is 'OFF,' and straight vertical is 'ON.' Make sure you set it to 'OFF' before connecting to the bike to avoid any arcing of the terminals. Also make sure the bike stays 'ON' when you jiggle the key in the 'ON' position so you don't have intermittent cut-outs while riding or cause excessive arcing, which could burn out the terminals.