Headlight switch - yellow wire repair

[disco51]

After switching out to the lower handlebars, I noticed my low beam headlight did not work.  After changing the bulb (not the problem), I noticed the light would work if I put pressure on the wires coming from the left hand headlight control switch.  I opened this up and found that one of the yellow wires has come unseated from it's soldering point.  There does appear to be a small cup the wire goes into.  Sure enough, when I place the wire in there, the low beam comes on.  But, it doesn't want to stay there - looks like the green wire is pushing it a bit.  So... question - I'm guessing I just need to solder this back.  I have never done this, nor own a soldering gun/pen.  I see they are cheap at Radio Shack.  How hard is this to do and should I source this out since this would be my first experience?
I can't seem to get through one project without creating another...  at least I'm enjoying the learning process although my wife wonders when I'm ever going to ride again...

[Barry]

Straightforward simple soldered joints are easy enough and a soldering iron or 3 are definitely tools I wouldn't be without.

Whether this is a straightforward simple soldered joint is another question.  It depends what the potential for heat damage is within the connector and also the likelihood of the solder bridging to adjacent connections.

Probably not the easiest joint to solder as your first attempt. If you know someone with good soldering experience I would get them to have a look at it before you dive in.  It might be easier after some dismantling of the parts.

[georgesgiralt]

If you dismantle the switch, beware there are springs and IRC a small bearing ball inside it... Better safe than sorry ;-)

[montmil]

If you dismantle the switch, beware there are springs and IRC a small bearing ball inside it... Better safe than sorry ;-)

Yep, that evil little spring will attempt to put the small ball bearing into a low Earth orbit just as the switch assembly is fully opened up. Strongly encourage you to put the switch assembly and your hands inside a large, clear plastic bag prior to your bride hearing... OH S**T!

[nhmaf]

It is kinda tight in there - I could solder it with one of my fine pitch irons for doing surface mount parts, but it only takes a slip to melt some of that plastic that helps to hold it all together.   I'd recommend *careful* disassembly inside of the plastic bag technique - trust me, you don't want to try it without one - and then you'll have room to properly strip back the wire insulation and repair the joint.  

Don't get a giant soldering iron either-but if you have a friend who is an electronics technician, they could solder this up for you in 10 seconds once the parts are out in the open.

[Matt Chapter]

Strongly encourage you to put the switch assembly and your hands inside a large, clear plastic bag prior to your bride hearing... OH S**T!

I wish you guys had told me about the plastic bag trick before I took apart the stop switch on my Honda.. that spring disappeared so fast!

Ah well, the contacts were worn so I needed a new switch anyways.

[montmil]

Strongly encourage you to put the switch assembly and your hands inside a large, clear plastic bag prior to your bride hearing... OH S**T!

I wish you guys had told me about the plastic bag trick before I took apart the stop switch on my Honda.. that spring disappeared so fast!

Ah well, the contacts were worn so I needed a new switch anyways.

Sorry about the Honda switch and that you missed the occasional plastic bag suggestion. But don't fall for the old "Let's play astronaut" trick...

...OK, Matt, you can be the astronaut.
Just slip this here plastic bag over your head and let me snug it down around your neck. [smiley=Norton.gif]

[Matt Chapter]

Sorry about the Honda switch and that you missed the occasional plastic bag suggestion. But don't fall for the old "Let's play astronaut" trick...

...OK, Matt, you can be the astronaut.
Just slip this here plastic bag over your head and let me snug it down around your neck.  

Would you believe that I never did well in my lessons?

I was taking apart the ignition switch (why is every freaking electrical connection on this bike loose or corroded!?!?).. Hey, look at this ball bearing! Pressed it in and spung there it went.

Eventually found the ball bearing, no dice on the spring.   [smiley=wall.gif]

[mrbuck]

I once took one of my  friends /6  handlebar swiiches  apart and had that little spring fly out the door into the grass! Needless to say it was never found.

Embarassment set in as I was the "pro" and he had no mechaical ability at all.  Solution...I took one of my Dad's old Zippo lighters apart and used the little spring that pushed the flint against the sparking wheel.  Problem solved.  

For those of you who don't know, that was the days before Bic lighters.

[montmil]

Tiny switch assembly springs n' balls disappearing forever into a parallel universe.

Handed rocker box covers installed on the wrong side of the engine.

These two goofs seem to be the most frequent of honest confessions. Bound to be others...  

[georgesgiralt]

Bic lighter also have tiny (and long) spring when using flint to light the gas on.
Maybe on the piezo ones there is a spring also but could be sturdier...
As for the tiny balls, every place selling ball bearing carry them in various sizes and in packets of 200 (often) and very cheap. This will give you plenty of opportunities loosing them and being creative as how you loose them...