Maybe try a larger washer on that post (and with a bigger hole so it can sit off-center and still fit there against the side rail) so the ball has the smallest gap possible but will still fit thru to the saucer. Is the ball getting stuck after it has flicked the switch and getting stuck on the other side of it? Ditto on the switch normally being longer and bending back into the slot. I seem to remember when I had my Xenon I had to mess with the switch too, like maybe using an extra long wire so the angle and leverage against the ball was as low as I could get it.