How To Repair Flasher Relay On A Scooter

Plow betoken flasher evaluation and repair

The flasher unit electronics slide out of the housing. There are two relays in the flasher unit. I call them the main and the secondary relays

Here is a functional schematic of the flasher unit. When the plough betoken is activated with the right hand side thumb switch the transistorized timer circuit in the flasher applies a pulsating indicate to the principal relay coil. This sends a electric current through the secondary relay scroll as well as lighting upwards the signal lights on the motorcycle. The secondary relay contacts are connected to the plough signal indicator light on the instrument panel.

If the contacts on the master relay are dirty or oxidized they may laissez passer plenty current to (weakly) illuminate the turn signals, merely not enough current to close the secondary relay and illuminate the instrument cluster indicator light reliably.

The stack of contacts and insulators on the secondary relay is some other trouble spot. If these insulators are degraded they will pass a little bit of current to the indicator bulb fifty-fifty when the plough bespeak is not actuated. The symptom will be a weakly glowing indicator lite all the time.

To outset the repair, remove the flasher unit from it'southward bracket on the left side (in this view) of the headlight tin can.

Annotation the rivet holding the contact and insulators together on the right side of the secondary relay. The original rivet is a hollow rivet, simply is not a pop rivet (shown here).

These are the main relay contacts. To polish them up for a low resistance connection just gently slide some 220 sandpaper through the gap while holding the contacts closed. Don't overdo information technology. This will probably solve the trouble of the indicator calorie-free not working even though the turn signals themselves are working.

Here the rivet has been drilled out. This hole is one/8" in diameter, so you lot will use a 1/eight" rivet to eventually reassemble everything.

Here are the ii insulators (on the left) a back up piece, and a silver plated contact. Note how the insulators are pretty shabby looking. They are made from some sort of paper and must have absorbed some h2o over fourth dimension because they are no longer practiced insulators. I was measuring 42 ohms across the contacts on this relay when the relay was open up. It should be an infinite resistance in that state.

I scavenged some new phenolic insulators from an old phono jack I had laying around. You could probably buy something similar at Radio Shack for a couple of bucks. Worst example, just use some fresh paper or mylar.

The hole in the silver plated contact is larger than 1/8". Information technology is imperative that the rivet does not bear upon the inner edge of the contact pigsty when the stack is riveted back together. This tin can be achieved by aligning everything carefully. I opted to put a picayune piece of thin tubing over the rivet as actress insurance against a brusk excursion.