Post
by DianneB » Fri Jul 17, 2015 11:52 am
Got the keys for the Honda Dream the other day so I was anxious to check out the electrical - there always seems to be electrical problems on old bikes. I hooked an old head lamp in series with the battery as short-circuit protection, made sure the ignition points were open, and connected my volt meter across the points to see if there was power to the ignition circuit.
There was only power in ONE of the six positions of the ignition switch! WTF??? In a different position, the headlight came on, but I never seemed to get power to everything.
Since the bike had been sitting for god-knows how long, I decided to clean the ignition switch. I noticed, as I was about to open it, that it had been opened before but I opened it, cleaned out the old grease, and polished all the connections before putting it back together. Still strange behaviour! I took the switch off the bike and checked it with a continuity tester and it didn't match the 'switch matrix' published on the web. Again, WTF????
I opened the switch again and studied the layout of the copper traces on the back plate (where the wires attach) and compared them to the spring loaded contacts in the plastic plate that is rotated by the key and it began to look like the plastic plate needed to be rotated 180 degrees - the way it was, the battery wire was only connected to other circuits in two positions.
Is it possible that the plastic plate carrying the contacts could be out 180 degrees? I carefully lifted the plastic plate out, turned it 180 degrees, and sure enough it mated with the key lock in EITHER position! I temporarily clamped the switch back together and did the continuity test in each switch position again. Sure enough it matched the switch matrix diagram now!
SON OF A BEECH! Who'd'a thought of such a problem! It took me 3.5 hours to figure it out and I am supposed to be "an electronics wizz".
I closed up the switch, bent the locking tabs down tight, and re-installed the switch before I had to leave off for the time being but I am confident it is going to work properly this time.