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Horn wiring and repair

Buellxb Forum

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drootang

Active member
Joined
Aug 3, 2023
Messages
29
My horn does not work. I confirmed the horn itself works with voltage. I disconnected the left hand controls harness and confirmed that the orange wire coming from the rear has power. I did a continuity check between the controls side orange/white and the yellow/blk that comes back from the controls and feeds power to the horn. This is an open circuit even when I press the horn button.

So either I have an open or the horn switch itself is corroded or something. All other left hand controls work correctly.

The service manual says the left hand controls cannot be serviced and should be replaced. But can I open the left hand controls and clean out the horn switch relatively safely? How likely am I to break something else that is much more important like headlights/turn signals?

This unrelated thread opened the left hand controls, so I gather it can be done: https://www.buellxb.com/forum/showthread.php?47699-LSL-Headlight-Motoscope-Mini-M-Lock/page2


Second, the yellow/blk wire that feeds power to the horn looks like it routes back through the main wiring harness all the way to the rear of the bike then loops back and returns to the front of the bike. Is that correct? Seems quite odd.
 
Yes you can pull apart that switch and clean the contacts with a wire brush. It's fiddly but just screwed together. It is also very common for that to happen on the right hand controls and the yellow button that activates the starter circuit.

If you screw it up, they are cheap to buy and easy to replace, or upgrade to something more modern:

https://www.buellxb.com/forum/showthread.php?56855-Update-your-XB-s-handlebar-controls!
 
2003-2005 ALL XB HORNS have 2 ground sources. 2006 and up do NOT

Your 2004 ground is via harness plug and mounting point on the S front cluster bracket---check both

Power supplied via KS relay early models....ACC relay later models. Remove both of yours...clean contacts...reinstall

Remove both screws holding left switch-gear housing together which reveals horn trigger button. Simple contacts and return spring. Clean with suitable electrical cleaner and toothbrush...clean again and lube...reassemble

Remove 10A horn/brake fuse....clean...check terminals...reinstall

Unbolt horn...clean mounting points....reinstall

Second, the yellow/blk wire that feeds power to the horn looks like it routes back through the main wiring harness all the way to the rear of the bike then loops back and returns to the front of the bike. Is that correct? Seems quite odd.

Not odd at all. Why? Because the horn and brake light circuit share the same positive feed source.
 
Cleaning the connectors on the horn itself and the switch inside the left control cluster solved it. Horn is working. Thanks
 
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