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1Back to top Go down   Repairing left switch block Empty Repairing left switch block on Tue Aug 25, 2015 8:58 am

Gaz

Gaz
Life time member
Life time member
In recent times I dismantled and cleaned/lubed the handlebar switch blocks and fitted headlight relays to my K75 during renovations and at the time I made a mental note to do the same job on my K1100 before I experienced any problems.

Alas! ........ too late. On the return from a recent visit to Waz and RT's places on the K1100 I was just into the night when I swung off the freeway about 3 kms from home and flicked my headlight onto high beam and was plunged into darkness. Some frantic operation of the dip switch while I was slowing down achieved nothing but I was able to pull up safely on the side of the road. More wriggling of the switch got low beam on again and I slowly rode home.

So it was time to do the business with the switch.
As I carefully dismantled the switch I was greeted with this small blob of metal resting in the horn button.
Repairing left switch block P8240421
Once I had the switch completely dismantled I cleaned the stationary contacts in the hi/lo switch section and could see that one contact was now down below the level of the housing and appeared to be where the melted metal had come from.
Repairing left switch block P8240422
This was preventing the sliding contact from making proper contact. I considered trying to build up the contact with some solder but felt that I would damage the plastic housing with the iron so I decided to try to replace the contact that was damaged. The sliding contact had cleaned up OK.
Here's a close up of the connections inside the left switch block for anyone who has not played there. The white/yellow wire is the one I need to work on.
Repairing left switch block P8240413
First up I cut the wire off at the connection post then used a dremel to cut the post off flush on the outside. I did this with very short bursts of cutting and had a damp rag handy to keep cooling it between cutting so as not to damage the plastic housing.
Repairing left switch block P8240414
This allowed me to set it up on the drill and using a 3mm drill bit I drilled out the contact.
Repairing left switch block P8240415
I looked around for something to use as a contact and found a brazing rod that was a whisker under 3mm diameter so I cut off a short section and tinned it so I could solder the wire back on.
Repairing left switch block P8240416
Repairing left switch block P8240417
Next I cut a small piece of wood the slide in the inside space to set the depth of protrusion of the contact inside then mixed up some 2 part epoxy and glued the contact into place.
Repairing left switch block P8240418
Here is the new contact before I cleaned a little bit of epoxy around the edges after it had cured.
Repairing left switch block P8240423
While I was waiting for it to cure properly I installed headlight relays on the K1100 then reassembled the switch and fitted it to the bike for testing. Happy to report that it is working fine (I hope it stays that way).

Cheers


__________________________________________________
Gaz
1990 K75 6427509; 1987 R80G/S PD 6292136; 2010 G650GS ZW13381; 95 K1100LT 0232224
    

2Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Tue Aug 25, 2015 9:36 am

RicK G

RicK G
VIP
VIP
That's what happens when there are no relays. I have used a dob of solder on the contact but as you said it is a bit of a chance if it gets too hot and the solder is too soft and wears away in a few years.


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

3Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Tue Aug 25, 2015 10:38 am

charlie99

charlie99
VIP
VIP
great fix gaz

cheers


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%ORepairing left switch block Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

4Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Tue Aug 25, 2015 4:28 pm

sidecar paul

sidecar paul
Life time member
Life time member
Repairing left switch block 112350 nice one.

Paul.


__________________________________________________
'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

5Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Tue Aug 25, 2015 6:46 pm

blaKey

avatar
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Life time member
Excellent Gaz. The photos are a great help.


__________________________________________________
Neil
K100RS 1986 RED!

Dress for the ride and the potential slide.
    

6Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Tue Aug 25, 2015 6:57 pm

indian036

indian036
Life time member
Life time member
Good work, Gaz.

Headlight relays was one of the early jobs on my K, partly just because of small wires and partly due to switch load. The fact that I also had a 100/90W bulb ready to replace the 60/55W bulb had a bit to do with it as well. 

Bill


__________________________________________________
1985 K100RT  VIN 0028991  My original Very Happy   (Historic rego)
1985 K100RT  VIN 0029036  BOB the Blue Old Bike  (Historic rego)
1990 K100LT  VIN 0190452  Work in progress
1984 K100RT  VIN 0023022  Work needing lots of progress

1986 K100RT  VIN 0090542  Work needing lots and lots of progress
1993 K1100LT  VIN 0183046  Work in progress
1993 K75S  VIN 0213045  Newest toy, slightly non-original
    

7Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Wed Aug 26, 2015 3:45 am

charlie99

charlie99
VIP
VIP
dito bill

these poor old eyes dont see too well at night time ...made a huge difference ...although noticing some burn-in - deformation of the mirror finish of the reflector after a few years of use .

relays were definately the wise option

cheers


__________________________________________________
cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%ORepairing left switch block Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

8Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Sat Jan 16, 2016 5:26 am

Waz

Waz
Life time member
Life time member
Mine just lost low beam on the way home, luckily still had high beam to get back.


__________________________________________________
1987 K100 RS
1997 R1100R
1996 R1100GS
    

9Back to top Go down   Repairing left switch block Empty Re: Repairing left switch block on Sat Jan 16, 2016 5:42 am

Gaz

Gaz
Life time member
Life time member
If it seems like the hi-lo switch is the problem Waz, good luck with the repair. DaleRT did a repair similar to me recently using a brass bolt to replace a contact.

Have you had one of those switches apart before? If not, disassembly inside a big plastic bag is good for catching bits that try to escape.

Don't forget to look into fitting headlight relays.

Cheers


__________________________________________________
Gaz
1990 K75 6427509; 1987 R80G/S PD 6292136; 2010 G650GS ZW13381; 95 K1100LT 0232224
    

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