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Old 07-05-2009, 04:16 PM   #1
jestephens   jestephens is offline

 
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Broken turn-signal switch spring

I cancel my blinker manually and religiously. It's a nervous 'tick' or something. ;) I've done it even before I lost the auto-cancel feature of the original blinker.
In fact just after finishing the project I submitted regarding an electronic blinker replacement, my signal switch broke! Worn out, the thumb lever became limp and lifeless, and ultimately useless.

"No problem," I thought to myself, "I'll order a new switch and be on my way!" You may have guessed, I found that the switch could not be bought alone but required the purchase of the entire left-side housing at a cost of $145. The problem then became a challenge.

Including a trip to the hardware store, I was able to fix the switch in under 2 hrs by replacing a spring ($0.29) and cleaning the contacts with a pencil eraser.

Maybe I'm the only one this has ever happened to, but I thought I would share this money-saving idea with others.

Disassembly
001: The left-side switch housing


002: Remove both screws clamping the housing to the handle bars


003: What you should see once inside the housing


004: Remove this screw


005: Remove the top copper plate


006: Once the copper plate is removed the spring is accessible. BE CAREFUL in removal of this spring. At the other end is a small ball! But don't fret too much, this ball can be replaced if lost.



Assembly
007: Push the new spring in place


008: Compress the spring while replacing the top copper plate


--Replace all screws to assemble--

Pictures 9-12 are measurements of the spring and ball components. You will notice, the spring I used to replace the original is not the exact same dimensions, yet works perfectly. A person could even buy a larger spring and cut it to length. That is what I did on my first attempt, but I cut it a hair too short resulting in barely enough tension to return the lever. Before I cut a new length, I found the spring I ultimately used. Also note, to [hopefully] avoid future spring failure by corrosion, I heavily coated my new spring with lithium grease, and likewise with my new chrome ball.








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Old 07-05-2009, 04:25 PM   #2
Cajunrider   Cajunrider is offline
 
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Broken turn-signal switch spring

That is very well documented J. I would have probably purchased the housing. I will bookmark this one. Thanks for sharing the instructions and pictures.

Mitch
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Old 07-05-2009, 05:23 PM   #3
rooster1   rooster1 is offline
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Broken turn-signal switch spring

Good info, Well documented.
 
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Old 07-05-2009, 05:57 PM   #4
macmac   macmac is offline
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Broken turn-signal switch spring

Nice work!
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Old 07-05-2009, 08:58 PM   #5
dogdoc   dogdoc is offline
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Broken turn-signal switch spring

Damn we have a mechanical genius in our midst. Very good work indeed J. Where did you buy the spring? where the ball? did you need the ball or just the spring? keep up the good work.

Dennis



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Old 07-05-2009, 09:06 PM   #6
jestephens   jestephens is offline

 
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Broken turn-signal switch spring

I bought the spring at ACE (the helpful hardware place). They also had individual ball-bearings so I bought one of those too, just in case I dropped the original during reassembly. ;)
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Old 07-05-2009, 09:12 PM   #7
ringadingh   ringadingh is offline
 
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Broken turn-signal switch spring

Its nice when you can fix it yourself and save a few bucks in the process.
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