Horn switch failure '09 - Yamaha FJR Forum : Yamaha FJR Owners Forums
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post #1 of 17 (permalink) Old 07-13-2019, 10:07 PM Thread Starter
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Horn switch failure '09

I have what seems to be a horn switch failure. I post only to see if there might be some mysterious alter-effect I don't know about.
Common with Hondas, the handlebar switches corrode and the regular fix is a shot of electronic contact cleaner. Having had three Wings, the starter, turn signal, and horn switches ceasing to work was almost routine, and a shot of the cleaner did the trick every time. If only it had worked on the front brake light switch! which the 18s ate like popcorn.
I changed my horns to PIAAs for an easy way out solution. They worked fine for a good while.
We were in downtown Chicago the other day and I did a test beep, having had many a vehicle horn go groggy from disuse.
No dice, only intermittent operation if at all. Contact cleaner was applied, to minimal avail.
The bike has not exhibited any spider bite symptoms in the 18 months/14,000 miles of my ownership. I did add an extra ground wire or two here and there along the way doing grip heaters and things like that; maybe I warded the bites off that way.
So I will pull the switchgear apart to see if I can fix the contacts. If not, off to Ebay for a new box.
I should have added horn relays, yes, but the other bikes in the garage complain about abandonment more loudly than does the Yamaha.
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Bill


2009 FJR1300
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post #2 of 17 (permalink) Old 07-13-2019, 10:54 PM
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I haven't heard of a horn switch failing on an FJR in all these years..... the PIAA's are drawing about the same as the stock horns..... let us know what you find....

Ray
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post #3 of 17 (permalink) Old 07-13-2019, 11:43 PM
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Best electronic contact cleaner, brought to me by an avionics bench technician: De-oxid.
Kinda expensive, but the better products usually are.
Cheers!
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If its got teats or tires, your bound to have trouble with it...
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post #4 of 17 (permalink) Old 07-14-2019, 09:15 PM Thread Starter
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Getting to grit

The corrosion on the contacts was beyond the reach of the contact cleaners I have on hand, so dismantling and some 120 grit sandpaper were in order.
Testing seems to indicate the cleaning was successful- the horns go off upon the first press of the switch. Given that the bike's in our townhouse garage, I couldn't really get carried away, so some on-the-road testing is needed.
As soon as the temps here get below 90F.
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File Type: jpg FJR horn switch repair 7-14-19 sm.jpg (108.1 KB, 15 views)

Bill


2009 FJR1300
2000 ZRX1100
1999 ZG1000
2018 Versys 650LT in the hands of the Missus
2004 Suzuki SV650S, also Hers
2006 GSX-R600, mixed ownership
In the avatar: 1966 Velocette Venom Thruxton and 1967 BSA Royal Star.
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post #5 of 17 (permalink) Old 07-15-2019, 02:44 AM
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Horn switch failure '09

Quote:
Originally Posted by Cherryriver View Post
The corrosion on the contacts was beyond the reach of the contact cleaners I have on hand, so dismantling and some 120 grit sandpaper were in order. Testing seems to indicate the cleaning was successful- the horns go off upon the first press of the switch.
Bill,

A horn relay will keep your horn switch like new for a good long time.
A new horn relay would cost less than the handlebar switch assembly, if it ever fails.
The horns would be louder, with the full battery power applied by the relay through heavy wiring (not the skinny harness wires).
But you knew that.
.
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Red
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post #6 of 17 (permalink) Old 07-15-2019, 09:04 AM Thread Starter
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Yeah, red, you're right. I just haven't gotten around to doing this bike.
It's sort of the red-headed stepchild in our garage and gets attention last.
Hopefully soon I'll have the fairing off for front brake line replacement and I'll get around to these sorts of things.

Bill


2009 FJR1300
2000 ZRX1100
1999 ZG1000
2018 Versys 650LT in the hands of the Missus
2004 Suzuki SV650S, also Hers
2006 GSX-R600, mixed ownership
In the avatar: 1966 Velocette Venom Thruxton and 1967 BSA Royal Star.
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post #7 of 17 (permalink) Old 07-15-2019, 09:44 AM
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Quote:
Originally Posted by RaYzerman View Post
I haven't heard of a horn switch failing on an FJR in all these years..... the PIAA's are drawing about the same as the stock horns..... let us know what you find....
My 06 just failed - there is no relay to switch the horns, just a pair of contacts.

You can just get a diamond contact file in there to clean and surface the contacts if you remove the switch from the handlebar cluster.

Funny that MamaYamaha uses a relay and complicated circuitry to switch the brake lights- 2 x 21 watt bulbs- but not for the horns!
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post #8 of 17 (permalink) Old 07-15-2019, 12:17 PM
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I would be surprised to learn that the contacts in the handlebar switch are not at least silver coated for corrosion resistance. I'd hesitate to sand that coating off and try crocus cloth or scotchbrite to lightly as possible clean the surface.

I really do not know, just an assumption on my part, and I know where that usually gets me...

If its got teats or tires, your bound to have trouble with it...
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post #9 of 17 (permalink) Old 07-16-2019, 03:46 PM Thread Starter
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I just gave it a hit with 220 wet-or-dry (I mis-typed 120). I'm not too worried about a surface treatment; if it fails again I'll be shopping for a different switch.
I should also add that access to the contacts was through the return spring. While it's possible to drive out the roll pin pivot and open it up further, I got lazy and just swiped away.

Bill


2009 FJR1300
2000 ZRX1100
1999 ZG1000
2018 Versys 650LT in the hands of the Missus
2004 Suzuki SV650S, also Hers
2006 GSX-R600, mixed ownership
In the avatar: 1966 Velocette Venom Thruxton and 1967 BSA Royal Star.
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post #10 of 17 (permalink) Old 07-16-2019, 05:21 PM
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Quote:
Originally Posted by barnstormer View Post
Funny that MamaYamaha uses a relay and complicated circuitry to switch the brake lights- 2 x 21 watt bulbs- but not for the horns!
Relays are not all that complicated. The brake light is a heavily used critical safety feature. Relay is essential for reliability.

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