82 Suzuki GS1100G - Horn button not working

[williamcryan]

Several months ago, my horn went out and I had been reading about the Stevel Air Horn and bought one to replace the ones that I have.
I don't know what happened in getting the wiring together, but the horn button no longer works. Before, it felt like there was a spring behind the button where it would return from being depressed and now it is limp.
I bought a replacement turn signal/light/horn fitting with the wiring harness with the objective of replacing the one I have with a horn button that works. I didn't see any easy method of dismantling the switch wiring board to get underneath it to find out what was wrong with the button.
I started to replace the old with the new and ran into a problem.
I have a wind jammer fairing and the new signal/horn unit has a different set of wiring and connectors than the one I have, even though it for the same year and looks identifical.
It seems that I need to find the turn signal/horn set that is wired for the Windjammer fairing. I don't see an easy way, especially since I'm not a wiring person to figure out how to convert the wiring harness connectors of the one that I have to the different one that I have on the bike now. Can an experienced electronics repair shop unsolder the wiring to check the horn button and put it back together?
I'm open for suggestions on what to do. I have what seems to be a brand new turn signal/light/horn set that I am not able to use. I'm going to see if I can find a correct replacement on Ebay.
I'm open for suggestions. Thanks.

[Agemax]

the horn button assembly will come out of the housing, it may be a bit fiddly but if somebody put it in there then it will come out!
it sounds like the spring behind the button has broken or seized up. try removing the old button from the inside and remove all the bits, clean them up and see what is missing or broken. then you can remove the button from the new assembly and rebuild your switch gear assembly with the parts required

[Redman]

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I have a wind jammer fairing and the new signal/horn unit has a different set of wiring and connectors than the one I have, even though it for the same year and looks identifical.
It seems that I need to find the turn signal/horn set that is wired for the Windjammer fairing. ........

Two topics:
1) why is the other unit differernt:

Turn signal / horn unit (left handle bar controls) will not be differernt on one 1982 GS than another 1982 GS because one has a Windjammer fairing. Windjammer fairing was added by owner after market. The wiring that needed to be modified to wire in the WIndjammer would be beyound the harness of the signal/horn unit.

Turnsignal portion of Turnsignal / horn left handle bar control maybe different because was from 1979 not 1982, but would aslo look different (turn signal swtich have more positions on 82 and head light switch differernt).
Maybe there was some other change between 80 or 81 and your 82 where it might look the same, but wiring differernt. (anybody?) (Steve will be along shortly, I suspect, to add or clarify or make exception.)

Maybe pictures might help.



and 2) How can swap the horn button?
I have not had the experince, so cant say.

.

[williamcryan]

Thanks for the feedback. I will post photos next week. The control unit looks exactly the same on the outside, but there is just a slight bit of difference in the wiring circuit control unit inside.
The main concern is that the end of control unit harness there is a plug in connector of a different size than the existing one that fits into the harnes for the Vetter fairing.
The new turn signal control unit is Suzuki Part 374-6 Tokairika.
I'll put a search on Ebay for different model when I have taken photos and more specifically identified what control unit I have on now.
I thought of fiddling, but I would hate to ruin the new one that I just paid $99 for.
I'll put this on hold until next week when i have some nice weather and get all the information together with photos.
Thanks for the feedback.

[Redman]

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The main concern is that the end of control unit harness there is a plug in connector of a different size than the existing one that fits into the harnes for the Vetter fairing........

The end of the control unit (signal/light/horn, left handlebar) should plug into the bikes wiring harness (not directly into the WIndjammer harness).

The Windjammer wiring should have one harness that plugs right into the headlight connector and an other harness that connectrs into the bikes wiring for the t/signals and instrument lights and main power and such. I would not think the Windjammer wiring would connect directly into the harness from the signal/horn left handlebar.

I could email you a 82 gs1100g suzuki schamatic. Buit it will be the same thing you could download from BassCliff BikeCliff website. The schematic shows the connectors.

.

[barnbiketom]

Lets go back to the beginning.

you said your horn quit and you got an air horn.

Did you install a RELAY so that the new air horn's CURRENT would not burn out the stock horn button?

If you did not install a relay, then you probably burned up the button spring and contacts.
The original horn draws very little current (AMPS).

any air horn I'd imagine , would draw much much much more CURRENT than the tiny original, stock horn button (switch ) will handle.

Imagine this.. The new AIR HORN draws 18 amps. ( just a guess) You hook up the horn to a battery with big wires and a 2 AMP fuse in series and try to blow the horn.

what happens??? the fuse BLOWS since the horn draws more than 2 amps.



your switch button was the fuse. you need a bigger switch or RELAY that is switched by the wee little horn button

[Brendan W]

Would anyone know the correct size of the ball bearings in the horn switch. I have removed a shiny 2mm and a badly corroded one which may once have been 3mm. Horn switch doesn't work. All the bits seem ok but clearly others have been this way before me and I suspect the 2mm is incorrect and I need two new 3mm.

[chuck hahn]

Ball bearing is from the turn signal switch I would say. seems youve got more than horn button problem going on in there.