True to the Motorola tradition of designing and manufacturing superior radio products, the HT1000, although an older model, remains in service around the world. It has become especially popular with Ham operators in recent years. Units, both VHF and UHF, are readily available at very low cost throughout the Internet.
Users and potential buyers often wish to replace the front cover of a well-used radio. There are a number of vendors of these aftermarket covers, particularly those made in China. These instructions/observations are meant to assist the owner(s) of older scratched or damaged radios in replacing these covers.
Ordering New Covers
Low-cost front HT1000 covers are available on eBay.com for under US$20.00 and are manufactured in China. They are sent via USPS at a very reasonable cost, and include the front cover, the volume knob, the channel select knob, the PTT lever and actuator seal; the universal dust cover, and in some cases, either supply the two front labels on a peel-off sheet or already affixed to the cover.
Removing Old Cover
As you will read, only very minor adjustments need be made to the aftermarket unit to create a very presentable, new looking radio. Couple this with a new inexpensive antenna and battery, and the portable HT1000 looks brand new.
Prior to and during the front cover change out, do not be in a hurry; have all the proper tools available; use extreme care in cutting, fitting, and gluing; and take special care not to scratch or mar the new front cover. A small piece of carpet on the workbench or work surface is always helpful while working with delicate projects. Some internal electronic parts are CMOS, so extra care must be taken not to create a static environment.
Also, the Universal Connector (for attaching accessories) must be removed from the old cover and re-used in the new cover.
The first step is the disassembly of the old cover from the radio. Instructions for this are available on the Internet, but generally speaking, a screwdriver is inserted into a slot on the bottom of the radio and the cover and electronics sections are “popped out” and separated. The FLEX is then removed from its captive connector and the two pieces are now independent of one another. The innards are then carefully pulled out from the old cover, being extremely careful not to damage or stretch the FLEX while doing so.
Use your fingers on the outside edges, then set aside the radio section. Be very careful not to touch any CMOS components.
Inside the front cover is the speaker with a retainer bracket; the microphone with rubber boot; FLEX connector for the Universal Connector; and sound dampening pad with adhesive back.
Remove the speaker retainer bracket using the Motorola instructions. Slip the Universal Connector’s rear edge connector out and away from its captive slots. With all the internal components free, remove the dampening pad using a thin bladed putty knife to very carefully slip under the pad to dislodge it from the inside cover. Carefully set aside these items, keeping in mind the fragile FLEX and its captive components.
Removing the Universal Connector
Now it is time to remove the Universal Connector. It is glued in at the factory and must be very, very carefully cut out using what I found to be the best tool – a razor blade box cutter with a brand new blade. Scoring around the outer edge of the connector again and again will ultimately dislodge the factory clue. As you score deeper and deeper, being careful not to slip and scratch the outer plastic of the connector, the blade will allow you to circle the connector and remove the connector. Once it is removed, the inner edges will need to be scraped clean of glue residue before it will fit the new cover. Repeatedly assessing the new cover fit may require a deal of skill. In some cases a Dremmel tool is necessary to very, very carefully remove a fraction of new cover material so that the connector and cover seat properly.
It is important that the old Universal Connector sits flat and level into the new cover cutout. If it is too high the accessory items (programming cable, remote microphone, et cetera) will not attach properly. Take care in scoring and gluing.
The old Universal Connector can now be glued into the new cover using a very thin line of Crazy Glue around the inside edge of the new cover. Apply strong and equal pressure on the connector until the glue has dried. This only takes moments, so take your time.
Once the connector is glued, it is time to replace the speaker, microphone and FLEX. First place the speaker into its area, then the dampening pad. Press firmly on the dampening pad to reseal what is left of the adhesive. Replace the microphone boot and slip the inner edge connector to the rear of the Universal Connector slot. Then reattach the speaker retainer bracket. All the new cover items should now be in place.
Joining the Radio and Cover
Around the outer edge of the radio is a contoured seal “O” ring. Assure that this seal is properly seated.
Carefully reconnect the FLEX from the front cover to the radio connector, assuring it is seated and attached properly. Note: If it is not, when applying power to the radio there will be no “beep” or sound from the radio. Set the top 3-position function switch to the mid position. Carefully slip the cover into the radio. At the bottom, prior to snapping the two sections together, use a small bladed flat-head screwdriver to push the rubber seal down and into the case. If not, it will become an impediment to snapping the two sections together.
Before reinstalling the knobs or antenna, attach the battery and turn the power switch ON. If you hear the “beep” you may continue to reattach everything else. If you do not hear the beep, something has become misaligned with the front cover FLEX.
Once everything is reattached, perform a test of the side buttons, the PTT, the channel selector and volume setting. You have now successfully replaced the front cover on your HT1000.
Notes and Hints
Save the old parts, they may be used!
The new covers make for a very tight fit with the radio contoured rubber seal. Finesse it into place.
The new replacement volume knob may have its orientation line in the wrong direction when placing it on the slotted shaft. Remove it and turn it 180-degrees or use the old knob.
The two pockets for the upper speaker retainer bracket may be a fraction short. Once the bracket is securely in place, using a small screwdriver, slip the bracket up and into the pockets for a more secure attachment.
The PTT actuator seal rubber tip may be an infinitesimal fraction too long, thereby holding the PTT wafer switch in the transmit position. However, in replacing two covers I found only one needed to be trimmed (which I did not – I used the old actuator seal) while the other worked right out of the box after a few hard pushes of the PTT lever.
When attaching the battery to the new cover, make sure both snaps are snapped securely in place. The new cover needs a short time to “work itself in” and the radio and battery may separate unexpectedly.
Motorola Hand Held Service Manual
Here is a FREE PDF download for the Motorola Jedi HT-1000 hand held radio service manual. Also included are other Motorola hand held models.