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Subject: E32 early models Ashtray repair Author: hairywithit : member since January, 2005 : 70 posts Posted on: 2006-01-07 04:27:35

Shogun's 89/90 750 had a sticking ashtray.
Here is how we fixed it.
Removing the ashtray assembly
Models: E32 (early models where the lighter raises up when you pull the tray out)
Tools: 8 mm socket and 10 cm hexagonal extension bar that can drive the socket
a really small open wrench that can drive the extension bar
this is what it looks like



1. Remove the IHKA panel
2. Position the socket over the hex heads of the 2 screws and use the spanner to drive the extension-socket assembly
3. Suggest that you bend the arm of the wrench -- not much force is needed to break the 2 screws free.
4. With the 2 screws out, the ashtray assembly can be turned and extracted.
No need to remove the console!!


Fixing the sticking ashtray
Models: E32
Tools: Small flat blade screwdriver and some epoxy putty (putty type and suitable for plastic)

Background: The lighter should rise up when the ashtray is opened. There is a pin on the lighter carrier that follows a track formed on the ashtray case.
Unfortunately, the track is weak right next to an internal light and if it breaks the pin jumps out of the track and jams everything up.
Easy to fix.
This what it looks like broken



1. Remove the ashtray assembly
2. Remove the metal ashtray
3. Pull out the traveling carrier gently -- you may need to raise the lighter with your finger to prevent it from jamming
4. Use the screwdriver to push in the two retainers (at the front on either side at the bottom) on the stationary carrier
5. Clean the broken track and surrounding area with ethanol
6. Mix a very small amount of epoxy putty and roll it into a bar about 3mm in dia and 2cm long
7, Position the bar behind the broken track and press it down till it fills the gap and provides a lot of support.
8. Use the plastic tool that came with the putty to flatten the putty so that it does not project above the level of the original tracks
9. Check that you have a smooth curve on the putty -- wait 30" -- reassemble and enjoy your never-sticking ashtray.
After repair

• E32 early models Ashtray repair (pic) - hairywithit 2006-01-07 04:27:35 (4766 views)
  • Thanks Hairy, here 2 more pics (pic) - shogun 2006-01-07 10:19:10 (798 views)