Another electrical issue ,not so weird (61322305292)

[frankenduck]

Got it apart cleaned it got it back together the plastic Protecting the soldered wires is gone should I put some silicone or something on it to keep it from being exposed ?

I'd use 5 minute epoxy. It'll hold up a lot better than silicone.

[beemuker]

I Reassembled  the switch and plugged it in to test it it works fine until I jiggle the wires apparently there’s a small amount of movement were the two pieces fit together and that’s causing The whack at least I know what the problem is but I don’t know how to fix it, I could try stretching the springs maybe that would hold it together tighter or glue the thing together so it doesn’t move but then I wouldn’t be able to to get it apart if it didn’t work

[Laitch]

I could try stretching the springs maybe that would hold it together tighter . . .

How many springs did you find when you disassembled that?

[beemuker]

How many springs did you find when you disassembled that?

4 , and there was no small ball bearing underneath

[beemuker]

The boneyard has one for $60

[Laitch]

4 , and there was no small ball bearing underneath

Some parts are missing. The 16V K100RS lock assembly has the same part number as yours. Filmcamera serviced his. Scroll down through his post about switch servicing to the switch assembly photos and compare your inventory with his.

[beemuker]

You are right as always Laitch. I am missing the spring that holds a little ball bearing that goes underneath ,it was not in there so this has been a part before.I probably have a snowballs chance in hell finding this little spring with a ball bearing in it. I was able to get the switch to work by jamming a small piece of plastic between the tabs so the two parts hold together without play . Testing it I haven’t been able to get it to whack. I’m calling it a day and I’ll test it again tomorrow , then put the moto back together and keep my eye out for a reasonable replacement. Thanks for all your help

[Laitch]

. . . I probably have a snowballs chance in hell finding this little spring with a ball bearing in it.

Review your ballpoint pen collection for a spring; take the piece with the holes in it down to an auto parts store or hardware store to find a bearing that will work with the spring. You might even find a spring, too.

I've got high hopes for this project, especially because you can buy a replacement switch. 

[Martin]

Try your local hobby shop for ball races that can be disassembled as used in radio controlled vehicles. Some cigarette lighters have smaller springs than ball points.
Regards Martin.

[frankenduck]

Time to install one of these:
https://gtmotocycles.com/products/motogadget-rfid-m-lock

[alabrew]

I just put a flip switch on the '91 after I broke the key switch.
It is mounted under the left handlebar.
If I park at a store, I turn the bars to the left to better hide it.
Not too worried about someone stealing her, most trips are to work and home.

[beemuker]

Thanks all for your help. I tested the switch again today before I installed it and could not get it to disconnect so I’m calling it good I’m going to button it back up.

[Laitch]

I’m calling it good

[beemuker]

Last issue was the ABS was faulting. Tested the relays and fuses, did the code read using a multimeter, 7dips, cleaned the brain connections, no
Love , so I pulled the A B S  relays and disconnect the brain, at least the lights don,t flash. I,m going to let the next owner deal with sending it off for repair if they want
Abs, this moto is too hot for FL so it,s for sale. I,ve got to hang my long legs out past the Tupperware, otherwise my knees burn.   I,ve. Got. An Rt  to ride while I look for a naked or nearly naked 75.

[frankenduck]

while I look for a naked or nearly naked 75.

Don't rule out a K75S.  Your legs are exposed to the elements so they don't leg burn like RT, LT and RS model K bikes.

I've frozen my knees riding a K75S in cold weather. I was just wearing Levis at the time and the only way to keep my knees somewhat warm was to warm up my hands on the heated grips and then grab my knees. Fortunately I had cruise control installed so I could alternate between the left and right hands to keep both knees kind of warm. It made for an interesting ride.

[daveson]

If the K1100 LT is like the K100RT you might have gaiter type things between the body panels and the forks. Removing them might be a big help in reducing the heat on your legs.