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S2forever
Posted on Tuesday, May 16, 2017 - 06:59 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

A car ran into me at rotary crossroad to break left turn signal. I replace it with brand new one that I bought long time ago. Well it broke at 1 mile(literally). Got back home and installed another new one. It broke in 2 miles(literally again). WTF!

It is time to do something.

This is turn signal stem from mgcycle(~$12) (Top: mgcycle stem mounted, Bottom: OEM stem for comparison);





It is the same part as OEM except how it mounts. Mold is a little rough but rubber looks like rubber, not brittle as OEM.
Cut it a little longer than OEM and ground to correct length with hand grinder, drilled and tapped(M12-1.25). All hand tools, no table machines involved. It can be easily made straight(90 degrees) by working from the back side.

This is how it looks with hollow bolt(you know what it is, don't you?);





I can't tighten it enough without stripping thread.
OK, I have two ideas to keep it in place(bond it or latch it with bolt), will let you know as I make progress.

(Message edited by s2forever on May 16, 2017)

(Message edited by s2forever on May 16, 2017)
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Tigermann
Posted on Tuesday, May 16, 2017 - 09:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

mgcycle shows the California III front signal which looks like it has the correct stem for our S2 units - so somebody in Italy is still making them. Or you could by this whole unit and swap out, I guess.



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S2forever
Posted on Tuesday, May 16, 2017 - 09:56 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It is quite expensive for a stem($~35). Actually I asked them if they are willing to sell stem only to be told no.
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S2forever
Posted on Tuesday, May 16, 2017 - 10:02 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I think it is not made by the same company(FAR, Italian company, I guess) who made OEM part. Probably it is Chinese.
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Williamscottrobertson
Posted on Tuesday, May 16, 2017 - 01:06 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If someone had time to dig on eBay, I'm sure they could be found. I found some with the long stem for a 90s triumph tiger, ordered the replacements from triumph and they were s3 signals. Anyway, it'd be nice to find a reasonable source for the short stems as they fit the bags on S2Ts, don't flop so much due to the length and would just be "correct".

http://www.badweatherbikers.com/buell/messages/476 23/787920.html?1484884687
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Sportyeric
Posted on Tuesday, May 16, 2017 - 10:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

A source for the hollow bolt is the innards of a household light. the part that holds the light to the outlet box. Sold in Home Depot.
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S2forever
Posted on Wednesday, May 17, 2017 - 12:56 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I think it is 10 mm instead of 12 mm.
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S2forever
Posted on Wednesday, May 17, 2017 - 08:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Not sure if one of ebay items fits S2T bag.
I have too many failed blinkers and want to recycle them instead of spending another $200 for a set.
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Tripper
Posted on Saturday, August 26, 2017 - 08:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I put NOS stock signals on front. Broke 2 in 2days. I think the plastic has become brittle with age. Now how to adapt LED. Anyone?
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Tripper
Posted on Saturday, August 26, 2017 - 09:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Discovered that my RH mounting hole is missing a metal bushing that is present in the left hole. That seems to be key to distributing the stress on the mount.
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S2forever
Posted on Thursday, September 07, 2017 - 09:24 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bought a hollow rod of aluminum at ~$10, whose dimension is 12 mm * 6 mm * 250 mm. Then brought it to machine shop:





Thread is M12 * 1.25, it is 40 mm long.

Coming soon(or a little later).
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S2forever
Posted on Saturday, September 09, 2017 - 03:17 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Installed threaded tube and locked it with small black flat head bolt (M2.5 * 8 mm) so that it won't rotate.
This is what I have got:





And this is how it looks on the bike:





I will do test ride next weekend to see if it stays put there.
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Williamscottrobertson
Posted on Saturday, September 09, 2017 - 08:31 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Awesome! I will definitely be attempting this! Where did you find the hollow threaded rod?
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S2forever
Posted on Saturday, September 09, 2017 - 10:45 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

There are a few Chinese sellers on Ebay. 12 mm * 6 mm (OD * ID). Wrong one arrived in 3 weeks. Correct one in another 3 weeks.
Did test ride today to find it worked. It just needs another small hidden bolt to stop whole thing rotating. I will do it in a week and post pic.
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S2forever
Posted on Saturday, September 09, 2017 - 11:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You have to fabricate it or stop by machine shop.
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Williamscottrobertson
Posted on Saturday, September 09, 2017 - 01:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ah ok, I misread the first post. So you had a machine shop thread it for you. Got it. I'll try to source some rod and do the same. Thanks!
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Williamscottrobertson
Posted on Saturday, September 09, 2017 - 01:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Also, maybe you could heat the rod and get the rubber to melt to it?
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Williamscottrobertson
Posted on Saturday, September 09, 2017 - 02:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I ordered the signal stems from mg and threaded hollow rod on aliexpress 10 pcs for $7, 40mm M12 threaded rod. We'll see what goes : )

https://m.aliexpress.com/s/item/32786850874.html?t race=wwwdetail2mobilesitedetail&productId=32786850 874&productSubject=10-pieces-lot-15-300mm-metric-m 12-whole-threaded-hollow-tube-threaded-rod-hollow- tube-DIY&spm=a2g0s.9042311.0.0.Ees1mA
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S2forever
Posted on Saturday, September 09, 2017 - 08:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Very nice find!
Its thread pitch is not specified. 1.5 mm pitch is most common for 12 mm thread while stock stem is 1.25 mm. So I would wait for them to arrive before drill and tap work.
In my case that small bolt goes through rubber and aluminum tube to keep them together. Steel will be harder to drill than aluminum with hand tools. Table drill machine would make it a lot easier.
Please keep posting your progress.

(Message edited by s2forever on September 09, 2017)
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Williamscottrobertson
Posted on Saturday, September 09, 2017 - 08:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Wilco. I think it's 1.0 pitch. I'll find out when I get them and post my results. Thanks for the idea.

William
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S2forever
Posted on Saturday, September 09, 2017 - 09:39 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

A small round head bolt(M2.5 * 5 mm or similar) goes into mating notch in the front fairing to keep it from pointing down or upward while you riding:



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Williamscottrobertson
Posted on Sunday, September 10, 2017 - 02:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Another good idea! Thanks!
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Dave
Posted on Thursday, September 14, 2017 - 10:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Clever - I like it!
DAve
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Williamscottrobertson
Posted on Saturday, September 23, 2017 - 08:59 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I got the stems and cut them short. I also got the threaded rods in the mail, as described. I'll go to the hardware store tomorrow and find the pitch.

Did you tap the rubber, drill it out, or just screw the rods into the rubber? I'm thinking about securing it with a few dabs of gorilla glue.
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S2forever
Posted on Sunday, September 24, 2017 - 09:04 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Drilled and tapped. It is easy. But lock bolt is relatively difficult with hand tools.
I also thought about bond. Still, drill and tap might be necessary.
BTW, my blinker still holds up strong after 1 k mile travel.
Let me know what you get.
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S2forever
Posted on Sunday, September 24, 2017 - 09:24 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you drill and tap with hand tools, do it from mount side. Otherwise you can't easily make it 90 degrees.
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S2forever
Posted on Sunday, September 24, 2017 - 09:36 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Don't let threaded rod bottom out and vibration transmit. I let it bottom out, marked it where it was, backed out 2 turns. I thought 2.5 mm (=1.25 mm * 2 turns) space may be enough for vibration to damp out on rubber stem.

(Message edited by s2forever on September 24, 2017)
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Williamscottrobertson
Posted on Monday, September 25, 2017 - 09:54 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Didn't do any drilling or tapping. I just pressed the stem into the rod in and threaded them in while the rod was held by the wrong pitch nut in a vise. My rod was 1.0mm pitch. Ace hardware had the nuts $2/ea :/. Anyway, some pictures to follow, I put some gorilla glue on the threads and screwed them down. Don't think they would bottom out, the rod is too short for that. Going to let the glue cure overnight and put them on tomorrow. Only the rears for now.

(Message edited by Williamscottrobertson on September 25, 2017)
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Williamscottrobertson
Posted on Monday, September 25, 2017 - 10:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)







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S2forever
Posted on Thursday, September 28, 2017 - 08:11 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Did you test ride? Does it stay put?
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Williamscottrobertson
Posted on Thursday, September 28, 2017 - 09:46 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I did test ride it. They stay put so far. I had to move my screws a bit to get them to line up with the notch. I wish I had left the rod out a bit further but i wanted it in as much as possible for stiffness.
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S2forever
Posted on Thursday, September 28, 2017 - 09:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

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Lynrd
Posted on Thursday, September 28, 2017 - 02:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That's what she said
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