disappearing spring in turn signal switch, NOOO!

[Iahawk]

my 84 Nighthawk has had a sticky turn signal/indicator switch since I got the bike 2 1/2 years ago. Today was the day to pull it apart, clean, lube and reassemble a sweet functioning switch. Disassembly was easy, and as expected it was covered in sticky, dry, 42 year old grease. Attached a few pics of the switch, then after removing the thumb switch what is underneath...and finally an exploded view of the parts.

The garage was cold and it was hard getting the pieces out...and as I pulled everything out and took a close look I realized the tiny spring behind one of the brass switches had flown away (red arrow in 3rd pic). Crap. Didn't see it anywhere.

So I'm off to the local hardware store today to see if they sell little springs in their hardware section.

If the hardware store doesn't have it...might have to buy a used switch to steal the spring from.  Any other ideas on where to get a replacement spring?

[Ruffus]

Try to find a ballpoint spring or canibalize a cheap chinese switch assy.

[Iahawk]

thanks for the suggestion, Ruffus. I tried the ball point pen but the springs were all too large. I then went to a local Ace Hardware and then a Lowes to look for springs and neither had them in a small enough size (Ace had a much better selection).

Then I realized the springs were sold/sized by outside diameter (OD). I needed a 3 mm OD compression spring. I didn't care as much about the length as I could cut anything down. I looked on Amazon and found some ranging from 1 spring to a pack of 10 for $6.99 USD. I then scrolled further on down and saw a 390 pack of stainless compression springs of all sizes for $6.59 USD.

So I purchased a lifetime supply of little springs. Delivery scheduled for tomorrow.

[Stig / Major Tom]

First - I'm impressed with Honda's build quality!
Also, I have had good luck on eBay finding pretty much anything I've lost or broken.
Stig

[Iahawk]

First - I'm impressed with Honda's build quality!

I was just thinking that! This switch has been functioning for 42 years. The only thing slowing it down now is the ancient grease that has hardened in it. I cleaned all the pieces so they look like new and added new grease. When I get my spring tomorrow I can put it all back together knowing it will work well for years to come.

This switch is almost identical to the switch in my 96 Helix (now 30 years old) that I cleaned and greased a few years ago. That one still feels like new. I'll add the pic of the Helix switch for comparison..

[randyo]

I did a similar thing, found the spring, but not the copper contact, luckily nearby an old UJM salvage yard, bushels of handlebar controls. I ended up finding a whole control pod in brand new condition for $25 for my '82 Yamaha XV920R

[Iahawk]

I ended up finding a whole control pod in brand new condition for $25 for my '82 Yamaha XV920R

nice score! I'd love to have an old motorcycle boneyard near me.

[Iahawk]

wanted to close this one out...received my lifetime supply of little springs today and I used a 3mm x 5mm spring. It fit perfectly. Strangely, this switch uses 3 different length springs and 2 different diameters. The 2 ball bearings appear to be the same.

I got the parts cleaned, greased (lightly) and assembled. I only dropped one of the springs with ball bearing twice...once on kitchen floor (found it under table) and once in the garage (found it in floor expansion crack next to bike). Someone was looking out for me today...

Pics - Laid all the parts out, assembled them, assembled part of it on bike, last pic is it all buttoned up. Switch moves much more freely, now. Feels like it should.

I'd never noticed that the switch housing has a hole in the bottom about the diameter of a pencil eraser. Presumably to allow water to drain out? This explains why you sometimes see spiders and mud daubers in these switches. There is a door wide open for them!

[Iahawk]

ran out of space...final pic

[Stig / Major Tom]