Bosch 1617 switch repair - Router Forums
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post #1 of 38 (permalink) Old 11-04-2007, 06:12 PM Thread Starter
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Default Bosch 1617 switch repair

Ok well tonight I went to use my router and suddenly..... no power. the switch stopped working. No amount of shaking or blowing out would get it going again. So I took it apart.

MAKE SURE IT's UPLUGGED AND YOU CAN SEE THE PLUG. I always do this. Not only unplugged but confirm that I know where teh plug IS before doing this stuff.

2 screws removed to take the top cover off. Torx. I shoulda wrote down the size.

Remove top cover.

Now you can see the speed control. In order to remove the switch you'll want to take out the 2 screws that hold the power cord in place. Torx again. Same size as the ones holding teh sub-base on. Loosen the power cord.

Look at the switch. It has 2 wires coming out of it. One is soldered to the switch and the other is on a spade terminal. The one that's soldered to the switch is connected to the router using a spade terminal at the other end. Trace that wire (easy) and pull that connection (spade terminal). Now lift the power cord out of it's spot and kinda flip it over the top of the router. The whole speed control unit lifts right out of the way as well. You need to do this to get slack in the wires going to the switch. Now you can just pry the switch out gently. First one end, then the other. When it's out away from the router housing a little bit you can disconnect the one wire that's on a spade terminal at the switch. The other one will snake out as you pull the switch away from the housing.

Now you have a switch in your hand. I put a multimeter on it and it wasn't passing power through (just using resistance testing). The rocker portion of the switch is just popped into the plastic switch housing and held in there by 2 little protruding "buttons" on either side. You can see them from the outside of the switch. Use a small, thin bladed screwdriver to gently slip between the rocker and the switch housing NOT IN THE MIDDLE... you don't want to damage those little buttons that hold it in. The rocker pops out and has a little post sticking straight down (into the switch).

My switch was full of sawdust. This switch isn't very well designed considering the environment it has to work in. I think Bosch has a newer model switch. I may call and see if I can get them to send me one. Anyways..... be careful because there's a little piece of metal inside the switch and it's not really held in there in any way. It just fits in there in a tab-and-slot arrangement. This is what "makes and breaks" to provide power. If it falls out.... (I blew mine out when I was getting the sawdust out)... it goes in just one way. There's a raised contact on one end that has to sit on a contact below it. This little metal piece is curved! If you're looking down into the switch, the curve goes AWAY from you. The post that comes down out of the rocker piece rides on the curve. It'll make sense when you see it. I had to get a tweezers to put it back in. Cleaned out the switch, popped in the rocker, tested with multimeter. Passed. Reassembly was reverse of disassembly. Router working again nicely.

I can see where this is going to happen again. Sawdust gets into the switch by slipping past the rocker. Only takes a few minutes to clean it, but it there's a new SEALED switch available, it'd only take a few minutes to CHANGE it and then I won't have to do this again
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post #2 of 38 (permalink) Old 11-05-2007, 07:04 PM
 
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Default Router Switch Repair

Hi, this problem seems real familiar. Well over a year ago I reported this problem on the forum. The switch 'failed' shortly after it's first use. I returned the router to the store and obtained a replacement from LOWES.

Again, that router switch failed. Numerous e-mails to Bosch and finally a response that they are investigating a new switch design. By the time I would have a replacement the warranty would have expired.

Back to LOWES and got a refund.

I purchased a CRAFTSMAN router (The exact same model as the Bosch).

That router had the same switch problem. Back to Sears, got a replacement (I purchased an extended replacement warranty). That new router also exhibited a faulty switch. I also went through cleaning the switch with canned air and so far the switch has only intermittently been a problem.

I am looking forward to see if the response from Bosch is the same or if a "New and Improved Switch" is available.

Since my Sears warranty has long expired, No chance in HELL would I have Sears attempt to repair the router.

I sent an e-mail to SEARS customer service and got a response that I expected - NONE. For me, the intermittent faulty switch is just an annoyance but, there is a much darker side to it - THE ROUTER CAN UNEXPECTEDLY START CAUSING A REAL SAFETY ISSUE.

All thy Best

Last edited by Birdflu; 11-05-2007 at 07:09 PM.
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post #3 of 38 (permalink) Old 11-06-2007, 09:00 AM Thread Starter
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yeah I raised that issue of a safety problem with Bosch. They only have until the end of the day today to be within their "response within 2 business days" claim.

DING! DING! DING!

As I was typing this, a response came in from Bosch.

***** pasting response from Bosch *****
Thank you for writing and for your comments. I will be sure to pass these along. For routers manufactured prior to June 2005 the switch was not internally dust sealed. Because of the situation you experienced, we did extensive testing of other vendor switches. June 2005 we changed to a new switch that is internally dust sealed correcting this problem.

I have ordered a new replacement switch for you. You should have this in 3 to 5 working days.

If you have further questions please write back.

Michelle
Bosch Customer Service

***** end paste *****

Thank you, Michelle!

Free replacement switch, free shipping. Bosch comes through again and no lengthy trip to a repair center. I'm still happy I bought this router and would buy Bosch again.
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post #4 of 38 (permalink) Old 11-06-2007, 09:04 AM Thread Starter
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Oh... and if the sears router is the same as the Bosch... that replacement switch is under $5. In case you want to have one handy.
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post #5 of 38 (permalink) Old 11-06-2007, 08:17 PM
 
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Just had the same switch trouble with my 1617 Bosch router, tried it out, worked good,a few days later went to use it, no workkkkeee. Retunded it to Lowes, got a new one, it's been doing good the past two months.
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post #6 of 38 (permalink) Old 11-08-2007, 01:23 AM
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I am curious to know if your routers are the "EVS" variable speed or single speed versions. I have a pair of single speed 1617's that have been flawless for many years.

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post #7 of 38 (permalink) Old 11-08-2007, 06:30 AM Thread Starter
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Mine is the EVS. The variable speed control is fine. It's a separate unit from the rocker switch.
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post #8 of 38 (permalink) Old 11-08-2007, 04:23 PM
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I have a brand new 1617EVS... I hope mine has the "new & improved" switch.

Thinking outside the box? What box?
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post #9 of 38 (permalink) Old 11-08-2007, 08:20 PM Thread Starter
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Quote:
Originally Posted by Roefa
I have a brand new 1617EVS... I hope mine has the "new & improved" switch.
No worries, mate. It's a 10 minute fix.

Nah... you should be fine. My EVS is one of the magnesium case ones. I don't have corrosion issues so I'm fine with it.
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post #10 of 38 (permalink) Old 11-11-2007, 02:15 AM
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Bosch uses different vendors to supply parts like everybody else, so a faulty switch is not a big surprise. The important thing is they promptly took care of the problem. You can't ask for more than that. They stand behind their products. It occured to me that the "many" years I have had my 1617's is actually 7 years. I am so comfortable with them I hardly remember the struggles with my old Craftsman.

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