Repair on worn indicator switch on LH switchblock.

Been making sure all the lights work, as I'm ready to submit my bike for a roadworthy certificate.

The indicators, turn signals, worked fine for the RH side, but not always for the LH side. I took the LH switchblock apart to see how it works. The indicator switch has a nylon block, that is moved left or right to activate the indicators. The nylon block is moved by the switch handle, which has 2 prongs to push the nylon block from side to side. The handle is pushed in to cancel the indicators, and the 2 prongs move the block to the centre, off position.

The top of the nylon block is shaped into an angle on each side, and I noticed that the angle for the LH indicators was more worn out, than the RH one, so the block was not moving across far enough to engage the switch contacts. Tried building up the angled top of the nylon block with Araldite. This has solved the problem for the time being, and the LH turn signals work fine. I'm not sure how long the araldite repair will work. I'll put some pics in, once my phone line is working again.

What the switch really needs is a new nylon block, but most likely not much chance of getting one. I would rather not have to get a whole switch block when that is the only problem with it. Maybe I will have to get a new switchblock some time, if the other switches wear out. Anyone else had this problem?

 

I suspect not a whole lot of folks have or have put 80,000KM on an XJ.

Might I suggest that almost any salvage bike probably has far fewer miles than yours, an assembly from a wrecker or off eBay would probably supply you with un-worn out parts.

 

My 88 model 900 had over 90K on the clock and my 83 900 had over 140K on the clock. Those bikes were revered over here as long distance sports tourers - and most of them were ridden accordingly.

But your best bet will be the wreckers. I suspect the Yamaha indicator mechanisms in the switchblocks of the late 80's are similar (if not the same), so if you have no luck finding an XJ9 switchblock, an FZR one will probably be interchangeable.....or definitely adaptable.

 

I thought it was fairly low mileage for a 21 yo bike, until I saw how few miles some of the bikes here had done when purchased. I put 220 000km on my previous work ute in 3 years. Think I will try cannibalising a switch from the wreckers yard. See if I can make a good one out of two. The headlight high beam flasher button took a bit of fettling to get it working again. I don't mind doing some soldering or wiring.

 

I adapted an FZR250 LH switch block onto my 750. It had all the same controls - just needed to cut / solder the wires to attach to the XJ connector because it was different (plug and pins were different). In fact most LH switch blocks across the Big 4 have the same functions, so you could grab just about any Jap one and adapt to fit.

If you go this way and have to cut / solder, a good tip is to cut each wire at a different length. That way the solder joins will be at different points and won't look like your loom is trying to swallow a golf ball.

 

This might seem a daft suggestion but can you make another nylon block or get a friend to make/machine you one?