Paul Geller said:
> I've now got my unit back with it's third rear case. They have yet to
improve the design, so I want to beef it up similar to what you
described to prevent another failure.
> Tell me please, after I take out the 6 rear screws, what else has to
come off to get the back off? I can't tell how it comes apart from the
rubber boot at the top, and wanted to avoid breaking anything.
> Paul Geller
I attempted to reply direct but the email bounced. It stated the mailbox
has been disabled; anyway other people may find this useful.
The rubber boot on the top is glued to the back cover. Some gentle
pulling and mine came off without a hitch. There will still be some wires
attached: the antenna, USB, and 4 pin connector. I did not disconnect
I'm afraid that you would like to preserve the ability to screw off the
button. With the fix I did the button is permanently glued to the rear of
Anyway, this is what I did:
After I ripped out the rear button there was a hole left behind where the
kept nut was located. I used a spare Dremel Tool cut-off wheel, the
reinforced fiberglass variety, as a washer behind the hole in the case. I
reduced the diameter of the cut-off wheel by cutting into some garbage
metal. I also cut a piece off of the wheel so there was a flat spot, sort
of "D" shaped. If you look inside the case behind the button this will
become obvious, as there is not much room for a washer above the button
I then glued this fiberglass washer inside the rear cover with a healthy
amount of JB-Weld two part epoxy. I also applied epoxy to the rear of
button where it meets the rear cover, and poked the stud on the button
through the existing hole in the cut-off wheel. I used the remains of the
kept nut behind the cut-off wheel to secure the button.
Silicone aquarium sealant was used to glue the rubber top piece to the
rear case. Make sure the rubber gasket between the halves is located
correctly, and screw the unit back together. Let it dry for a day or two.
As a test I pushed as hard as my fingers could and the button did not
budge. It has been on a couple dirt bike rides and no trouble so far.
If your unit is not broken and you would like to retain the thread-off
feature, I imagine you could scuff up the area around the kept nut and
then apply some JB-Weld around the nut for support. There is plenty of
room back there to do so.