The power cord on my Dyson DC04 has split though the outer insulation, and I have no doubt that the inner insulation will go at any time ,causing a short, please could anybody tell me how to remove the switch housing to gain acsess to the power cord terminals so I can cut back and re make the power cord terminals.

Kevin Gregory, January 2005

Mmmm had a go at this. The insulation on the power cord had been pulled to expose the internal wires so it needed tiying up.
I broke the switch surround - but Dyson will supply a replacement for £5

Simon, October 2007

on the top of the switch look to the left as you are standing behind the cleaner you will see a small hole about a millimetre wide slide a sharp knife down the left directly inline with this , inside the switch housing not inside the assembly housing, and use a pair of wide angle pliers to gently ease the switch out , underneath is a star tool screw , undo this and the entire assmebly will slide out

Nemesis, March 2007

The best reference for this job I have found is at http://k.domaindlx.com/aspViper/Personal/Dyson/switch.html

Whoever said James Dyson was a great designer has obviously never had to change one of these switches.

Steve Dooley, August 2006

Hi, Just go to www.dyson-online.com and check out their technical advice section. The site is fantastic! Good luck.

Charles, January 2006

Here is a reliable method of removing the yellow switch cover without breaking anything.

1. Get hold of a 120mm length of 1.6mm diameter sprung steel wire. I got some from a model shop.

2. Make a bend 20mm from the end at about 45 degrees.

3. Make another bend at the same end 6mm from the end by a further 25 degrees.

4. Use a good light source so that you can clearly see down the side of the switch cover.

5. Use a small terminal screwdriver to gently open up the gap between the flat side of the switch cover and the grey surround.

6. Insert the 'release tool' that you have made sideways into the gap.

7. Rotate the tool so that the bent end pushes against the barb on the switch cover. The 'shaft' of the tool should locate in the small notch in the grey surround.

8. You should be able to see the barb getting pushed in. You can continue to use your terminal screwdriver to help hold the gap open so that you can see what is going on.

9. Using a narrow wood chisel between the switch cover and the surround at the front of the Dyson, carefully lever the cover upwards. Wear some protective gloves if you think that you may slip with the chisel!

10. As soon as the barb has passes the lower edge of the surround you can remove the release tool and the cover will come out easily.

11. You now have access to the switch and cables.

Kevin, July 2005

someone told me to poke an 'implement' down the slot in the body adjacent to the flat side of the button.No luck with a straightened out paperclip yet. They say that after an internal catch is released you just pull off the button. Best of luck.
please let the rest of us know what the secret is! if you manage it....

dave, January 2005