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June 2nd, 2015, 05:20 PM   #1
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I Ride: 2005 FE650e
2005 FE650e horn switch not working

Hello,

Just installed a horn on the bike (it came stock with one, but the previous owner removed a bunch of stuff, including the horn). After wiring up the new horn, I tried to test it. It let out some faint whines... then nothing.

I checked the handlebar switch with a multimeter... turns out that the switch itself is dead (red isn't connecting to brown as per the diagram).

Any tips on how to fix the switch? It seems like a self-contained unit.

Thanks.
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June 3rd, 2015, 04:57 PM   #2
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I don't know anything about that switch. I would play with each wire with meter/tester. If you can take it apart I would. Could be a bad condition at wire/switch point. But first put 12V to horn see if it works then start on switch. Sorry I can't be more helpful. Make sure you have a good earth/ground
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Last edited by Rainerio; June 4th, 2015 at 07:20 PM.
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June 3rd, 2015, 05:24 PM   #3
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Hi, thanks for the thoughts. The horn is good, it works. I tested the connection on either end of the switch using resistance...

when the switch is off/un-pressed:

in - out --> infinite resistance (good)

when the switch is on/pressed

in - out --> still infinite resistance (bad).

This tells me that either the switch isn't closing the loop or that the 14" of wire connected to the switch has gone bad. More likely is that the switch died. I'll see if I can split it and clean it out somehow.
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June 4th, 2015, 05:04 PM   #4
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Fixed it.

Problem was a bent and dirty momentary switch inside the unit. Put a bend in the piece of steel on the inside and it's good.

In the process I had to drill out some rivets to break the unit open.

Inside there are two balls (ball bearings) that float in grooves, pushed by little springs. When I took it apart, it sort of exploded and I lost the steel balls for a while.

In the end it was pretty simple, just some headaches along the way. To seal it up, I used super glue (since the rivets were toast).
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June 4th, 2015, 07:18 PM   #5
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Good for you. Most wiring is simple after you find it. It's the finding that can make you nuts
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