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LM1 horn/flasher switch cable routing question.

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TheWrongTrousers View Drop Down
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    Posted: 22 Feb 2019 at 17:40
This has got me foxed. Can anyone help ?

I have finally got my hands on some pretty decent and functioning standard switches. I think I can see that the rotating light switch and the horn flasher switch are intended to fit together. There is a sort of semi circular recess within the rotating switch into which a similar shaped bit on the horn/flasher switch fits into and they see to want to be together, one within the other 

I can see that the wires from the light switch must exit in a sort of cutaway in the clutch lever bracket. No problem with that (hopefully). 

My question is this. What route do the wires from the horn/flasher take once they are on the handlebar. I am going to attempt to attach some photos to show you what I am going on about.  As you can hopefully see in the photo, the wires seem to be going in the direction of the light switch which is to the right of the horn flasher switch. However, if they go in that direction there is no room for the two switches to fit/lock together.  I guess they could go left in the direction of the handlebar grip but that seems to make no sense at all.  

I hope I have explained this clearly and it makes sense. Does anyone have the answer ?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 17:46
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 17:48
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 17:52
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 18:03
As you can see from the third and final pic, the wires quite like the idea of going through the middle of he light switch and if they do that, the two switches fit together nice as you like, but that can't possibly be right can it ... i mean, where would the handlebar go ??
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 1down5up Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 20:42
they go into and through the handlebar. The left clip on should have 2 holes in it, one for the indicator/horn wires and one for the lights wires. 

Right clip on only has one hole for the starter switch wires

If your clipons don't have the holes you will need to find some. Drilling will be difficult, as if you don't get the spot correct the swit he's will sit to far apart or at a funny angle. 




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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 22:13
Really ?! - I am stunned by that information. Is that right !? So, if the wires go into the bars, where to they come out ?

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mike H Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 22:24
Yep each LM clip-on handlebar has a hole under the switch, the wires go through the hole into the interior, then up the midde of the clip-on then come out of the top end of the tube via a rubber grommet / bootee type thingy.

HTH

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mike H Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 22:31
RIGHT, eventually found this photo, so you can see the wires come out the top ends of the clip-on handlebars with rubber sleeves.




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Post Options Post Options   Thanks (0) Thanks(0)   Quote 1down5up Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 22:54
Originally posted by TheWrongTrousers TheWrongTrousers wrote:

Really ?! - I am stunned by that information. Is that right !? So, if the wires go into the bars, where to they come out ?


They come out the top end of the bars, and the wires need to be removed from the molex connectors everytime you want to take the switches off, including if you want to take the brake master cylinder or clutch assembly off..... 
 

The LM2 & LM3 have the same clipons but without the holes... So if you have the original style of bars they may be from a LM2 or LM3. 

What bike have you got, is it an original LM1? 

To potentially add more pain, the original switches earth through the bars, so they need to be chrome or black zinc. I think all the red lemans had chrome bars and the blue bikes had black zinc (at least my 77 blue lemans had black zinc bars from new) 

To be honest unless you are going for a full original 850 le mans resto I would use newer more reliable switches. The original switches are nice because they are dainty, but they are delecate, poorly earthed and prone to leaving you somewhere with no lights/kill switch etc


Edited by 1down5up - 22 Feb 2019 at 23:01
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Mike H View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mike H Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 2019 at 23:16
I'm getting confused, this is an actual LM, not another model that's been made to look like? There is at least one such of the latter also being discussed on the forums! Confused

Bwain 'urts ...

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Post Options Post Options   Thanks (0) Thanks(0)   Quote 1down5up Quote  Post ReplyReply Direct Link To This Post Posted: 23 Feb 2019 at 01:28

Here is one on ebay, hope the link works... 







Edited by 1down5up - 23 Feb 2019 at 01:32
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TheWrongTrousers Quote  Post ReplyReply Direct Link To This Post Posted: 23 Feb 2019 at 08:31
Thats all very helpful, and I am very grateful to all for your kind assistance. I do seem to have later bars on my bike. The frame number is VE16847 and it seems to be LM1 in all other respects.  It came with later switch gear on it, but as we know, lots of them have later switches for all of the usual very good reasons. I guess a lot can happen in 40 years. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Chris950s Quote  Post ReplyReply Direct Link To This Post Posted: 23 Feb 2019 at 11:39
Yes the cables run inside the handle bars with those early switches, just like the did originally on my 850T. I have retained the switches (but not the light switch) and added external cables that run outside of the clip-ons. As I no longer have indicators I use that on the LH switch for main/dip and the kill switch on the RH side is lights on and off.

They look period but yet another trap for any potential rivet counter! Big smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Jools Quote  Post ReplyReply Direct Link To This Post Posted: 25 Feb 2019 at 15:42
Many years ago I had a brand new Benelli 250-2CE which had these self-same switches.

I would honestly recommend that you don't use them - they were horribly unreliable even when brand new, and using dip/main beam at night would frequently leave me (literally) in the dark until I found the precise point at which the contacts lined-up. There seemed to be no 'positive stop' to prevent one from going either too far or not far enough when rotating the switch.

I solved the problem a while later when I crashed it heavily, wiping the controls off both sides of the bars, and then replaced all the swichgear with that from a Yamaha RD250! 

Problem was that I'd sold it to my brother and crashed it on the way to deliver it to him!!!
Jools

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