I took apart my turn signal and horn assembly.

[frijoles-and-beans]

Wow, I can't believe I found it. It's smaller than what I was thinking. I used one of those little telescopic magnetic things for working on cars like a small metal detector.

Whew, ok, I have all the parts now, but I'm going to have to actually put it together now. Can anyone tell me which spring goes to which area? I don't think it was quite clear to me in the thread that goes over this. I have been attempting to fit them into their places, but I'm not sure I have it right. I do have all 6 springs; it's just these three that are giving me trouble. The three springs that I have in place are the two for the turn signal contacts, and the one for the horn.

[frijoles-and-beans]

Ok, I think I have it figured out now. The small fat one in the middle goes with the ball-bearing, the long thin one on the bottom in the picture goes under the top of the turn signal switch and the other one on top in my pic goes on the switch itself in that little space in the middle. Am I right? I don't know, but I'm about to attempt a re-assemble.

[BigD_83]

Ok, I think I have it figured out now. The small fat one in the middle goes with the ball-bearing, the long thin one on the bottom in the picture goes under the top of the turn signal switch and the other one on top in my pic goes on the switch itself in that little space in the middle. Am I right? I don't know, but I'm about to attempt a re-assemble.

Beans and Beans...is everybody out of hibernation in New Mexico now? Good to see you back on here.

I don't know the answer, but I'm going to pay attention to what you do. Took the 650 out for it's first ride in a long time last night, and I hadn't noticed when I brought it home, but either the springs in my controller have seized/broken or were taken out by a PO.

[Nessism]

Ok, I think I have it figured out now. The small fat one in the middle goes with the ball-bearing, the long thin one on the bottom in the picture goes under the top of the turn signal switch and the other one on top in my pic goes on the switch itself in that little space in the middle. Am I right? I don't know, but I'm about to attempt a re-assemble.

Great job. Now take it back apart and scrub down those crusty metal contacts with a scotchbrite to remove the corrosion. When reassemblying use some dielectric grease.

[Charlie G]

http://www.thegsresources.com/_forum/showthread.php?t=151173&page=2

F&B take a look at post #9. There are some pictures that might help.

cg

[frijoles-and-beans]

Boom! I did it! It's all back together again.



The horn is sounding good. The signals and the headlights are working fine, and the switch is springing back like it should. Nessism, I'll be a little more thorough next time maybe. I know where everything goes now, so it wouldn't be a big deal anymore.

I did use a wire brush to scrub the contacts. I even took that little switch out that's part of the high-beams and scrubbed out the contacts on either side there.

I have it back together and I'm happy for now.

[GateKeeper]

Good Job........

[frijoles-and-beans]

You know, the only reason I even thought about doing this is because I was messing with the right side of the handlebars with the start button and the kill-switch. There was some corrosion on the contacts that I got rid of, so I thought that the other side of the handlebars would be just as easy. I thought wrong. It was a lot more tedious.

Well, I'm glad that's over with, whew!

[robertbarr]

Well, I'm glad that's over with, whew!

Hey, congratulations!

Next time, break out (or borrow!) the Dremel tool with a miniature cloth buffer wheel. The secret weapon to reworking bike electrics. It turns the copper (or brass, or whatever it is) shiny, brand new looking.

I did the same thing with the earlier bar control, from the '79 or so. Photos here:

[bonanzadave]

[frijoles-and-beans]

Is everyone telling me what a mediocre job I did?! Argh!

Naw, I know I did a quick job of it, but it really was a nice job on the contact area. Ok, so don't look back at the pic I posted of the circuit board. hehe

[Killer2600]

On topic of these switches, does anyone know if replacement parts can be obtained? The horn button and parts are missing on my bike - I bought the bike this way.

[Charlie G]

Someone a year or two ago was making the little plastic buttons on a garage lathe.

cg

[argonsagas]

Is everyone telling me what a mediocre job I did?! Argh!

Naw, I know I did a quick job of it, but it really was a nice job on the contact area. Ok, so don't look back at the pic I posted of the circuit board. hehe

I thought it was a good job, and am glad you tackled it with success.

I have never had to open the horn. It may, apart from the ignitor, be the only part on the bike that I never disassembled.




For future reference, here is a bit of advice I have offered more than once over the years:

Get a large, clear, plastic bag.

Put the switch/part inside the bag, along with necessary tools.

Move the part to the closed end of the bag

Put your hands inside and work on it.





Simple? Yes, but when springs and bearings decide to part company with the original members of the cast, and utterly abandon their role(s) in the play, this works to keep them within arms reach and you can coax them into another performance.

[frijoles-and-beans]

For future reference, here is a bit of advice I have offered more than once over the years:

Get a large, clear, plastic bag.

Put the switch/part inside the bag, along with necessary tools.

Move the part to the closed end of the bag

Put your hands inside and work on it.

You should've seen me taking the thing apart. I started on the right side with the start button and the kill-switch, so I assumed that the other side was in similar form. I didn't realize how many small pieces were in there. The pieces just popped out all over the driveway. I can't believe I even found all them all. Some of those pieces were pretty tiny.

Thanks to everybody that helped me to put it back together. I'd still be on it, no doubt.