This is the Escapades of the GCRad1 2016 Yamaha TW200. If your reading this post first and want to know the whole story, start with Part #001 covering how I came about purchasing the “new-to-me” 2016 TDUB with 318-miles on the odometer in July of 2017. I also cover the bikes I’ve owned leading up to the TW200.
PART #001 – New To Me 2016 Yamaha TW200 & How I chose to TDUB

Turn Signal Switch Service

The previous owner had a nice tumble in the sand of Pismo Beach. This resulted in a turn signal switch was stuck in the right-turn ON blinking position – ALL THE TIME!

Before any riding on public streets could happen, fixing this turn signal switch needed to happen right away! After several attempts at spraying the switch out, I knew what what going to happen next. I should have taken photos from the beginning. But you know how it is… You get all excited about a new bike – I JUST WANT TO RIDE MY NEW BIKE!

This first photo was after cleaning it two or three times. Yet the TDUB’s turn signal switch is not cooperating! Well, it’s fully cooperating… it just will not stop cooperating when I tell it to!

Eventually, through he process of taking the turn-signal apart, cleaning, greasing and re-assembling, and digging down further. I made my way to the very bottom layer of the handlebar mounted switching mechanism. Everything is coming apart at this point! This is going to take longer than anticipated! I have to remind myself – PATIENCE PLEASE! Do it right!

At the very bottom is where the real switching work is done! Up top is all the cool mechanical stuff, but here is where the real sticky issue is happening!

Sub-assemblies within sub-assemblies! After a few attempts of spraying out the sand, the only solution was to pop it open and get “them little sand critters out!”

With the TW200’s switch fully disabled, I can get to the gritty-grit! Also I can see just how this little item handles the functionality of switching from left to right turn signals.

The bottom of the switch bucket was full of crust and grim. After opening it all up, it’s obvious the previous owner was attempting to spray out the sand. They used some type of super syrupy orange juice with magma-pulp. My solution was to run it under warm water with a thick coat of self bubbling hand soap. 

I have the bottom bucket portion of the switch assembly fully cleaned and dried. Now I can start putting the Japanese kindergarten jig-saw puzzle back together. First in is the horn button.

Next is switching system dropping back into place. Why yes, that is a judicious amount of dielectric grease applied to the switch.

With the switch in place, it’s worth the effort to manually test the switch. The photo about is of the switch in the middle position.

Here the TW200 signal switch is the Left turn signal position.

Here is the TW200 switch in the Right turn signal position.

You can see the switch down in the bottom of the case and in next is the mechanical – metal movement. It’s interesting how the brass pins passing through the plate. These pins are actually what moves the switch left to right with the centering ability.

This is a two part piece that has to go in at the same time. There is a spring loaded bearing in the white plastic piece I am holding. For the whole mechanism to fit into the house, it needs a little attitude to slide in. This “attitude” tension in the “switch” is needed so it doesn’t flop around.   #HowThingsTick

All the bits back into place – but wait, there’s MORE! :rolleyes:

We are getting close to buttoning it all back up, but we have to lay all those wires back in…

And those wires need to be covered and secured!

Wires covered as such.
Give it a quick test before covering everything entirely.

Then the final protective cover in set in and bolted down. The quick test prior to installing proved positive and now the TW200 turn-signal switch assembly is ready to be reassembled to the handlebar! You know what this means!

Now I can ride on the street without looking like a dork! But the TW200 does not have a turn signal self-cancelling mechanism, so only if I switch the turn-signal off after making any turns. But too, maybe we do forget to turn the signal off in our sheer excitement of riding… it happens!

Someone has to make a turn signal cancellation device?!


PART #001 – INTRO ESCAPADES OF THE GCRAD1 YAMAHA TW200
PART #002 First Fix – ESCAPADES OF THE GCRAD1 YAMAHA TW200
PART #003 – ESCAPADES OF THE GCRAD1 YAMAHA TW200 PART

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