Replacing handlebar switch assemblies


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brschillinger
Posts: 6
Joined: Sat Jul 17, 2010 4:35 pm
Location: Clarks Summit, Pennsylvania
Motorcycle: 1994 GL1500 Aspencade
2006 Royal Enfield Bullet

Replacing handlebar switch assemblies

Post by brschillinger » Tue May 17, 2011 8:42 am



After a failed attempt at repairing the hazard flasher button on my '94 Aspencade, I opted to replace the whole turn signal/high beam/hazard switch assembly. I checked the Steve Saunders site and tried following the threads found there. My problem is being able to reach the plugs on the cable ends where they connect above the radiator fan. I have removed the fairing front cover, under cover, radiator shroud, both fairing lower covers, read side covers, front side cover, fairing inner cover, ignition switch cover, top inner covers and the top compartment. I've loosened the radiator (without removing hoses, so it's not completely out of the way) and still I can't seem to be able to get my hand in to reach the connectors. While I think I can release the connector locking tab from the outside of the connector holder, I am not sure how I would feed the new connector back into the proper position.

Has anyone else done this and how much of the "tupperware" did you have to remove? Is it necessary to remove the main fairing? I have also removed the headlight assembly as I am planning on upgrading the bulbs to Sylvania Silver Star Ultra's and need to adjust the windshield height tension levers, so the mirrors are also removed. Is it that much more work (and would it be worthwhile) to remove the instrument cluster and main fairing?

Thanks for any assistance!



raycw
Posts: 127
Joined: Wed May 19, 2010 11:02 pm
Location: Jackson, CA
Motorcycle: 88 GL1500

Re: Replacing handlebar switch assemblies

Post by raycw » Fri May 27, 2011 11:50 am

You are soooo close!!

All you need to do now is to pull the fan motor. Not both… just the one that has the wires for your switch that you're replacing.

The fan motors can be a little intimidating but you don't have to pull the fairing and you've probably got more plastic removed now than you really need.

The fans are snug… both coming out and going back in. Especially when reassembling it helps to lube the snot out of the frame and the fan.

On the bottom of the fan housing is a 'plastic protrusion'. It fits into a rubber grommet… you'll see it when the fan comes out.
You gotta make sure to get the protrusion back into the grommet when you slide the fans back in…. they won't fit right if you don't.

brschillinger
Posts: 6
Joined: Sat Jul 17, 2010 4:35 pm
Location: Clarks Summit, Pennsylvania
Motorcycle: 1994 GL1500 Aspencade
2006 Royal Enfield Bullet

Re: Replacing handlebar switch assemblies

Post by brschillinger » Tue May 31, 2011 7:09 am

Thanks for the reply. I did remove both of the radiator fans - the turn signal wiring harness has a connector on each side of the bike and I was also replacing the cruise/starter switch assembly as well. Removing the fans made it possible to easily reach the connectors, and you are right, they are a tight fit. I also removed the instrument cluster as it made it easier to gain full access to the wire harness ties. I was able to undo the ties without removing the instrument cluster, but it was much easier refitting the ties with it removed. In retrospect, the time spent would have been significantly less if I had just removed the few extra pieces (fans and instrument cluster) at the beginning instead of trying to get by without removing them.

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Stew
Posts: 32
Joined: Mon Oct 23, 2017 10:40 am
Location: Smokey Point, WA - USA
Motorcycle: 2000 GL1500 SE
2005 CRF230F

Previous bikes
2004 Polaris Sportsman 90
2003 Honda Ruckus
1993 Honda Elite SR
1986 Honda CR125R
1979 Yamaha GT80

Re: Replacing handlebar switch assemblies

Post by Stew » Fri Nov 17, 2017 7:00 pm

raycw wrote:
Fri May 27, 2011 11:50 am
You are soooo close!!

All you need to do now is to pull the fan motor. Not both… just the one that has the wires for your switch that you're replacing.

The fan motors can be a little intimidating but you don't have to pull the fairing and you've probably got more plastic removed now than you really need.

The fans are snug… both coming out and going back in. Especially when reassembling it helps to lube the snot out of the frame and the fan.

On the bottom of the fan housing is a 'plastic protrusion'. It fits into a rubber grommet… you'll see it when the fan comes out.
You gotta make sure to get the protrusion back into the grommet when you slide the fans back in…. they won't fit right if you don't.
Old thread I know, but you get another thank you! I was starting to worry how much more stuff I was going to have to take off to get to those connectors but you're right, those radiator fan shroud assemblies do come out but they are in there snug to be sure. Now I can finish replacing the turn signal switch assembly :)
Winging it every chance I get

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MikeB
Posts: 1882
Joined: Fri Dec 04, 2009 12:54 pm
Location: Tacoma, WA
Motorcycle: 1998 - GL1500 Aspencade.
2003 - GL1800A

Re: Replacing handlebar switch assemblies

Post by MikeB » Fri Nov 17, 2017 7:47 pm

Yes, it is an old post but it is good that you found it.

I have to tell you though, removing the fans is just as big a pain as removing the fairing, if not more so.

I replaced the left handlebar control and a guys 2000 SE a year and a half ago. Didn't remove the fans but did take all the bolts out of the fairing and lifted it so I could get my hands in there. Cable routing was the main reason I lifted the fairing. Once the cables were routed, tied off and connected, things went back together pretty quickly. Had pretty much all the plastic off from the fuel tank forward.


MikeB
Tacoma, WA, USA

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