Quoted from Freedom:Can someone please let me know about the fix-mod to get the inner orbit switch registering ?
Love this game.
Shooting the inner loop on my Rush Premium was registering only about every third time I made the shot, and after researching the problem here and elsewhere, I was buying into the "airball" theory.
But after spending waaaaaayyyyyy too many hours thoroughly troubleshooting the issue both on the game and on my kitchen table with a multimeter, I learned that the switch doesn't register consistently for a combination of reasons (none of which are "airballs").
First, I ordered and installed the magnetic replacement switch from M&M Creations. No luck. In fact, that switch wouldn't register at all during a game. It would, however, register, in switch test mode, when I waved a screwdriver or other metal object over it... just not a pinball. I removed the M&M switch from the machine and broke out the multimeter. Turns out the M&M switch is a normally closed switch that opens if a metal object --other than a pinball-- moves over it. I tried chrome pinballs, carbon steel pinballs, cheap ball bearing pinballs, rusted pinballs, magnetized pinballs, demagnetized pinballs... no pinball will trigger the M&M Creations switch; has to be a screwdriver, pliers, or other metal object. Weird, but then, I'm not that well-versed in conductivity and magnetism - could be that I received a faulty switch from M&M Creations.
Next, I put the multimeter on the stock Stern (500-9935-04) switch that came out of the game. It checked out as closed, whether or not the actuator on the switch was pressed.
So I ordered two replacement 500-9935-04 switches from Pinball Life. Before installing, I put the multimeter on both of them... same issue... both checked out as closed, whether or not the actuator was pressed. After scratching my head for some time, I took a pair of needlenose pliers and bent the actuator blade slightly up off the actuator button on one of the new switches, and bingo! It became a normally open switch that closed when the actuator was pressed... now I was getting somewhere.
Or so I thought.
Once I wired the new 500-9935-04 switch in and secured it to the playfield, the switch was locked closed and wouldn't change states when the actuator was pressed. Turns out these microswitches are so delicate that just removing or installing one can alter the actuator and turn it into an "always closed" switch. The tolerance is practically microscopic, and the way it fits in when screwed into position can also lock it closed if the wire bend is touching the wood under the playfield.
Finally, the actuator arm doesn't protrude high enough out of its slot in the playfield when the switch is installed - I had to bend the wire part of the actuator arm (strategically, in several places) to get the switch to register consistently without ambiguity. Having gone through all of that, I now have the switch registering every time the ball rolls over it in gameplay, no matter how fast.
So... the problem isn't "airballs" flying over the switch and not tripping it; the problem is state ambiguity within the switch itself (the switches simply aren't reliable) and the tight tolerance within which it needs to be adjusted both above and below the playfield to avoid said state ambiguity. Bottom line: bad microswitch design, bad design on Stern's part in choosing this particular microswitch. And for what it's worth, some of the current "fixes" being offered ($$$) to address the issue simply won't work. Until a reliable solution comes along, the fix is going to be trial-and-error removal, bending, and refitting the stock switch until it works reliably and consistently. Quite a pain in the ass.