How to repair the faulty switch in your vacuum cleaner

ID: 193178

Description: [youtubevideo|_SrykcV9vck]Use this guide when...

Steps:

1. Unplug the vacuum from the mains before doing anything else.
2. Remove the hose, dust container, filter and any other loose accessories so they do not get in the way.
3. Work on a clean bench with good light to avoid losing small parts.
4. Lift out the primary filter to reveal the screw heads holding the upper case.
5. Locate the three screws around the motor compartment.
6. Undo all screws and keep them organised for reassembly.
7. Separate the two plastic halves; the compact design may need gentle wiggling to release hidden clips.
8. Carefully remove the motor block and attached wiring to expose the internal switch and cable connections.
9. Set a multimeter to continuity and verify the mains cable conductors are intact.
10. Test across the motor terminals to confirm the motor is not open-circuit.
11. Probe both poles of the existing switch; no beep indicates an open switch and confirms the fault.
12. If the switch shows no continuity in either position, plan to replace or bypass it.
13. Use any on-off rocker or slide switch rated for the motor’s voltage and current, even one salvaged from a small lamp.
14. Ensure the new switch fits somewhere on the housing even if it differs from the factory part.
15. Untwist or desolder the two leads that originally went to the faulty switch.
16. Join each lead with a short pigtail that will reach the new switch, twisting them tightly.
17. Secure the joints with small insulated screw terminal connectors for a solder-free, vibration-proof hold.
18. Verify no bare conductor remains exposed to other components.
19. Clip off any protruding tabs of the original switch so the space is tidy and closed.
20. Route the joined cable toward the cord entry point so the new switch sits where you can reach it while cleaning.
21. Leave enough slack in the cable to strip, crimp and move the switch without tension.
22. Score the outer sheath with a utility knife and peel it back to reveal the brown (phase) and blue (neutral) wires.
23. Use a wire stripper to remove about 7 mm of insulation from each core without nicking the copper.
24. Inspect the strands; damaged conductors can overheat and must be cut back and re-stripped.
25. Identify the common side on the switch that makes and breaks the circuit; this is where the brown phase lead must go.
26. Insert the stripped brown wire under the correct screw terminal and tighten firmly.
27. Connect the blue neutral lead to the permanently linked side so it remains uninterrupted.
28. Repeat on the opposite terminals for the outgoing motor leads, matching colours brown-to-brown and blue-to-blue.
29. Pull each wire slightly to confirm the screws have gripped the copper.
30. Place the motor back into its cradle, keeping wires clear of the fan and bearings.
31. Align the two housing halves, ensuring seals and catches seat properly.
32. Re-fit every screw you removed earlier and tighten until just snug to avoid cracking the plastic.
33. Reconnect the mains plug, press the new switch and confirm the motor spins evenly without sparks or smells.
34. If the cleaner runs, unplug it again and refit the filter, hose and accessories.