New Start / Horn Buttons

[bonanzadave]

Mr. DPage has created new Horn / Start buttons. The factory buttons must get old and brittle then break. Ive lost both of mine. Dave sent me one of his buttons and it works great.

Heres the thread that got him started.....
http://www.thegsresources.com/_forum/showthread.php?t=121546&highlight=button

Heres a shot of his new button and my old broken button.

Horn and Start are the same

 

[DanTheMan]

I see you're harboring alien pests on your controls.......

 

[doctorgonzo]

I can't believe the condition of the lettering. Mine is long gone, spare I bought a while back is long gone as well.

 

[Charlie G]

I took my left control apart to clean the horn contact, as the horn was barely audioable. Two things happened. Parts went flying and the blinker/dimmer button broke. I glued the dimmer/blinker button (I hope it holdsray together ( the pryimid shaped one). Part of the tee on it's underside broke off. I put it back together and it worked. I got all (?) the parts back in. There is no stopping point for the blinkers, to stop at in a neutral (non-signaling)position. A slight cross wind and I'm signaling a turn :-k.

The question I pose to all of you is...is there suppose to be a ball bearing inside that switch? I found one a week later and I bet it is a stop detent for the neutral position. I really didn't get to see where all the parts went before it exploded into bits. I don't want to take it apart again unless I have to. Thanks all.


Charlie g.

 

[Skateguy50]

I had issues with mine as well as the kill switch, got a momentary push button off the shelf at radio shack and soldered that in. The kill switch I think would light up if i wired up the ground, might do that for the novelty effect but it works good enough.

I was afraid if i wired it up it might light when the bike is off, but probably shouldnt lol.

http://www.radioshack.com/product/index.jsp?productId=2062522

and

http://www.radioshack.com/product/index.jsp?productId=2062545

not exact fits but I made them work.

 

[bonanzadave]

is there suppose to be a ball bearing inside that switch?

Yep. Sure is. Ill send you some pics and hints for reassembly when I get some time. Gotta run now.................

 

[Charlie G]

Thanks....We'll wait.

cg

 

[Guest]

At least the ladybug likes it. :-\\\
Good job!

 

[bonanzadave]

The question I pose to all of you is...is there suppose to be a ball bearing inside that switch?

Yep. Sure is. Ill send you some pics and hints for reassembly when I get some time. Gotta run now.................

Here is the inside of the LT control. The bigger black assy is the turn sig contact and the smaller one below is the hi/low headlight contact. The spring on the turn sig contact is the hi/low headlight return spring.

The ball bearing youre missing goes inside the turn sig contact on a spring and is the detent for LT, Auto LT, RT, and Auto RT switch positions. If you lost the ball you may have lost the spring too.

If you take the turn sig contact off you see the turn sig return spring under it. The best advice I can give is have a clean well lit work area. Use Dielectric grease to hold things together and a tooth pick to set and move the tiny parts around. And a lot of patience !!

 

[Charlie G]

Spring has sprung?

Spring has sprung?

bonanzadave,

Thanks for the pictures. Mine dosen't have auto turn but looks quite simular. The part numbers for a 650g and 1100e are different. I went out to the garage and actually found a spring. Are there three springs in yours? Looks like one sits under the black piece and moves it left to right. The one with the ball bearing is it under the black piece as well? I guess I'll pull it off again and see if this make sense. I hope I'm not missing a third spring. Finding a ball bearing after being unknowingly lost after two weeks and then a spring after three weeks was pretty high odds. Finding another spring ....I'm not making bets. Thanks again!

Charlie G.

 

[bonanzadave]

Are there three springs in yours? Looks like one sits under the black piece and moves it left to right. The one with the ball bearing is it under the black piece as well?

Wow ! Congrats on finding those little parts. Mine actually has 5 springs. The 3 you see in the pics and 2 more tiny springs under the contacts. The spring and ball go into a hole in that black piece.

 

[Charlie G]

I think I remember the other two springs. I'll pull it apart when I feel I have the patients for it. By the way, when I was comparing part numbers for your switch and mine, I noticed part numbers for the following:

24 37311-49000 BUTTON, HORN 1[COLOR=#00800] NOT SHOWN , [/COLOR]25 37312-49000 SPRING 1[COLOR=#00800] NOT SHOWN , [/COLOR]26 37313-49000 CONTACT 1[COLOR=#00800] NOT SHOWN [/COLOR]
I presume 25 and 26 are horn button parts. Info from "ALPHA SPORTS"

Thanks again

cg

 

[Steve]

Info from "ALPHA SPORTS"

Keep in mind that Alpha is a good source for information and parts numbers, but they tend to be VERY expensive.

.

 

[trumpetguy]

So bonanzadave, you successfully re-assembled the LH switch? I have one in pieces right now, with a new button from dpage. I have been playing with the pieces. I think I have five springs and one ball.

Are there two balls or just one? (I have the same switch as yours)

Is there anything other than the spring under the button? If not, what makes the contact?

 

[bonanzadave]

There are 6 springs if you count the horn.

1.The spring and one ball for the turn sig detent.
2. The high / low return spring for the headlight
3. The LT / RT return spring for the turn sig
4. Two contact springs under two small copper contacts
5. The horn button spring.

I should make a movie. Im getting pretty good at putting the thing back together.

 

[trumpetguy]

So there's nothing under the horn button other than the spring?

I think I have all the parts! Now for some dielectric grease and lots of time too fart with it...maybe at Thanksgiving. I'll take lots of pictures.

Thanks for the help!

 

[Charlie G]

Trumpetguy,

There is a little copper disc, which sits on top of the horn button spring. It completes the circuit, from the spring to the curcit board.

cg

 

[trumpetguy]

Trumpetguy,

There is a little copper disc, which sits on top of the horn button spring. It completes the circuit, from the spring to the curcit board.

cg

Does the disc have a hole in it to fit the small peg in the bottom of the button? Or does anyone have a picture or measurements of it? I need to find a replacement to work with the replacement button dpage made.

 

[Charlie G]

It's been about three weeks since I had mine apart, combined with poor memory..........There wasn't a hole in the disc. I don't remember a peg in the button, it would make sense that there might be one. It would keep the disc oreinted properly. The copper/plated disc had a dimple in it. I'm sure the pointed side went down, toward the spring, to make contact with the circuit board. I wouldn't be hard to make. I have a "whitney punch"( like a hand held paper punch for metal), for making small holes in sheetmetal. It leaves a dimple in the waste for the hole, which would probally work. I didn't measure the disc, but I will be taking mine apart again soon to install the ball bearing and spring, which decided to explode into nowhere. If your not in a hurry, I'll measure mine when I take it apart and punch one from some scrap copper I have and mail it to you. On the other hand, if you knew the size, and there was a sheetmetal shop around you which worked in copper, they might make one for you. In a pinch, tin snips, a hammer and a nail set would work. I'd choose the hammer method!:-\\\ I am a carpenter, afterall. Give me a PM if you need a hand.

Charlie G.

 

[trumpetguy]

Charlie,
A measurement would be great -- I could make one or find a substitute somehow. I am in no hurry as I bought a spare switch so I'm riding the bike.

I just want to be able to contribute a little -- I'd like to do a write-up with pics on replacing the horn button. Now that dpage is making replacements, we don't need to discard switches just because the horn button failed.

Thanks to everyone for the help on this little project!