Stallion Info

[WildBillH]

Re: Stallion Repairs & Trouble Shooting

Would a Hydraulic Brake light Switch resolve part of the problem with the elements causing the switch to go bad?

Switch $9
Tee for hydraulic Brake switch $4

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

It would make a lot of sence to me to use a pressure switch.

I raised my #530 today and looked at the brake switch. Wow, not well designed. I have one that is blue and white and works off the brake linkage and a paddle. The switch is compressed and in the off position until you push the pedal and then the paddle opens the gap and allows the switch to push out and actuate the three circuits. The center plunger on the switch does not even line up correctly with the paddle and when operated, the entire switch moves front to back, i.e. not mounted firm in the bracket (bracket held on with two screws to the frame).

The electrical connection and cable plug-in, which faces forward, opposite the plunger, presses directly onto the frame. It would appear to me that it is being crushed because it does not look like a 90 degree connector.

The electrical leads or wires look like they are not watertight, no rubber boot, in the plug and the wires are no bigger than 22 to 24 GA, very small. I can not understand the factories comments concerning the current issues with the interim switch that I was suppose to have. I would almost believe that I have the original switch because the body of mine certainly does not appear to be watertight. I did not remove the switch and look inside for grease. There does appear to be a slight red substance around the frame in this area but I did not inspect for grease.

I guess I can see why the new mod will be spliced into the existing cable and replace the electrical connector on the switch.

 

[WildBillH]

Re: Stallion Repairs & Trouble Shooting

Does anyone see a reason why a hydraulic Brake light Switch would not work and remove the mechanical one. Has anyone tried it?

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

TM has told me that the blue and white switch that I located is the cruise control cancel switch and not be brake switch. What a bad design idea when the brake switch could have done the same thing through a relay or a computer control device.

The brake switch is outboard the cruise switch, is square, black and apparently comes directly off the brake booster?? I will crawl under today and see. I also found out that the intermediate brake fix switch had the switch body bolted together and not snapped.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

I looked back under my Stallion and finally found the brake switch. It is black/rectangular and I do have the second gereration switch because it appears to be watertight and has nuts and bolts holding it together. It is outboard the cruise switch and slightly higher and more to the rear.

The factory informed me that it is under rated and the contacts can not handle the current or arc.

Does anyone know the NAPA part number of a suitable substitute?

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

TM has just sent the latest replacement switch to my dealer and I will be the first candidate for the replacement tomorrow morning.

I previously had the interim waterproof switch that failed (about 10 to 30 trikes) due to arcing/current with the cable spliced for the new o-ringed connector so I just need the switch not the cable replacement because they used an upgrade to the interim switch by silver plating the contacts, so I am told.

The majority of the trikes will therefore need the cable connector spliced in to the existing cable for the new switch. I will post as much info as possable after tomorrow to detail the new switch number and manufacturer.

I do know that my current interim failed switch is bolted together by about 6 nuts and bolts. I would assume that the new one is also.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

I just got back home from the dealer and the brake switch install. It went just as planned. All he had to do was remove the old first generation waterproof switch and install the new one that TM sent him yesterday.
I did not get to see the new unit, but I believe it is the same outside as my old one. If I get under my unit, I will do a visual and report if it looks different from the outside.

He also took out some caliper spacers from the right rear due to grinding noises that I was having when making a right turn.

Let's see if any of this works this time.

 

[Road Runner]

Re: Stallion Repairs & Trouble Shooting

My cruise control failed last week on a 10 day ride to Arkansas. Brake lights work, comes out of park, just no cruise. #533 is now at Ford dealer to repair the cruise. Will report back on the parts needed, later on.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

Per my previous post on the cruise control, there is a blue and white switch toward the inside of the break linkage that is suppose to disengage the cruise control, similar to the third wafer of the break light switch. This switch is not watertight and the connector plug presses directly against the frame every time the brakes are applied. I would look there first then test the break light contact for the cruise.

 

[silverdevil]

Re: Stallion Repairs & Trouble Shooting

cruise switch #5 has now gone out on #538, it was picked up late April and 6 months later I have gone thru 5 cruise switches. location, location, location, bad location for this switch which is not weather protected in any shape or form.
#4 was rubber coated and lasted 6,000 miles, by far the longest.
#5 when installed has a tin box installed around it yet it still only lasted little over 1,000 miles.
I am suppose to show up at TMS tomorrow but it is a 50/50 chance for rain so it may be later in the week before I get there.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

Sorry to hear of your problems.

I believe as long as TM continues to do an excellent job of listening to the owners, their product quality will improve and the bugs will get worked out just like the foreign manufacturers did.

I own high end Lexus vehicles and traded in a late model Goldwing for my Stallion and they all have had issues. It is how the issues are resolved that matter to me so I will continue to be a Stallion fan.

 

[Road Runner]

Re: Stallion Repairs & Trouble Shooting

Put the Stallion up on ramps today, to see how the cruise & brake switch are mounted. Its just kinda hanging out there with no protection. Not a good design. Ford dealer fixed the cruise, says there appeared to have been an impact with an object kicked up from road. Bent the switch bracket and broke the switches. Bottom line, costs me $700. to repair, warranty would not pay for poor design, only for failed Ford parts. They covered NONE of it.

Am wondering if some sort of protective shield could be made to protect the switches. Has anyone done that?

BTW, found 2 grease zerts on the u-joints. Did you all know they were there? Dont remember reading about greasing them in the owners manuel.

 

[Gorilla]

Re: Stallion Repairs & Trouble Shooting

The fittings have been there on all models. There also are some on the steering which are much easier to get to. I was told to service them by my dealer when I purchased it. The ones on the u-joints are very hard to do.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

I can not find anything in the maintenance schedule to lube the U-joints, but there are many entries to inspect the U-joints and to lube the steering linkage.

 

[Gorilla]

Re: Stallion Repairs & Trouble Shooting

you can probably do it every 10k

 

[Papa Zook]

Re: Stallion Repairs & Trouble Shooting

I have found a solution to the chronic reliabity problems that works for me.
EVERY time we take a long ride, something malfunctions. Really getting tired of the problems.
Solution # 1. Park it in garage, cover it, then ride my Goldwing.
Solution # 2. Bought us a toyhauler, now when we are far from home and it breaks down again, load it up and drive home. No more getting stuck out on the road, far from home, with a vehicle that is not fit to ride back.
I wish this were not the case, but see no cure coming from TBMS.

I have gotten nothing but excellent co-operation and support from Jeff & JD at TMS. Why don't you try calling JD and discussing your issues with him? JD is Jeff Vey's son and the chief Stallion project engineer and is very much on top of resolving any issues with the Stallion. I think you will find that he will bend over backwards to make it right.

 

[Papa Zook]

Re: Stallion Repairs & Trouble Shooting

Put the Stallion up on ramps today, to see how the cruise & brake switch are mounted. Its just kinda hanging out there with no protection. Not a good design. Ford dealer fixed the cruise, says there appeared to have been an impact with an object kicked up from road. Bent the switch bracket and broke the switches. Bottom line, costs me $700. to repair, warranty would not pay for poor design, only for failed Ford parts. They covered NONE of it.

Am wondering if some sort of protective shield could be made to protect the switches. Has anyone done that?

BTW, found 2 grease zerts on the u-joints. Did you all know they were there? Dont remember reading about greasing them in the owners manuel.

In all fairness, an object kicked up from the road should be covered by your insurance company and not the factory. There is plenty of clearance but anything can happen as far as a road hazard. I do think it would be fairly simple to fab a simple protective plate though.

 

[Papa Zook]

Re: Stallion Repairs & Trouble Shooting

Not trying to kill the thread guys just voicing my opinion just like you are.

 

[Gorilla]

Re: Stallion Repairs & Trouble Shooting

Stopped at Russel's and Libby's Friday. Russel showed me the new brake switch. It sure should solve the water problem. Russel says they will be available shortly as they are being made.

 

[Mattel]

Re: Stallion Repairs & Trouble Shooting

Someone makes a heavy duty skid plate. I think it is Southwest. That may cover the part you want to protect. I hit a stick and blew out a new tire comming back from a repair and warranty did not cover it. I was only driving to get it fixed, but it was a road hazard, not a defect in the tire.

You cannot armor plate every part on a stallion, but you can try. I can see how it would blow if it was my $700.00 and I would be pissed too. But I had half of that so I half way know how you feel.

 

[deb54]

Re: Stallion Repairs & Trouble Shooting

Just wanted to say that we returned from a 2 weeks ride up north - about 2500+ miles. The Stallion performed great. No complaints or problems. Had a great time and many, many stares, pictures and inquiries. It's cool being different!
That being said, I do have the problem with the body pulling away from the inner lining on the side of the hood. Hubby spoke with a Headquarter guy at biketoberfest and he is making sure Russel has all the necessary equipment for the repair.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

Just wanted to say that we returned from a 2 weeks ride up north - about 2500+ miles. The Stallion performed great. No complaints or problems. Had a great time and many, many stares, pictures and inquiries. It's cool being different!
That being said, I do have the problem with the body pulling away from the inner lining on the side of the hood. Hubby spoke with a Headquarter guy at biketoberfest and he is making sure Russel has all the necessary equipment for the repair.

Tell Russel to use the 3M 8115 product that TM recommended to me. Mine was excessive and so far it has held with this product. Look at my post for under "plastic shell" for info.

 

[CAS]

Re: Stallion Repairs & Trouble Shooting

Stopped at Russel's and Libby's Friday. Russel showed me the new brake switch. It sure should solve the water problem. Russel says they will be available shortly as they are being made.

I have had the new switch for about a month and it is still hanging in there, but I have not been in the rain but it appears to be very watertight.

You may need the new cable if your's did not have the first fix installed.

My issue was with current and arcing across the contacts and the new switch contacts are now silver plated.

 

[deb54]

Re: Stallion Repairs & Trouble Shooting

New issue:
Left fog lamp burned out today. Is there a bulb in there that can be replaced? Nothing in the owners manual. I read a post in another thread from back in June and someone said you need to remove the whole assembly and solder in a bulb!!?? Really?

 

[Gorilla]

Re: Stallion Repairs & Trouble Shooting

Yes really or replace the whole assembly. Actually you can replace the bulb and cut and connect new feed wires. Find someone that has some wiring ability and it should not be a problem to fix.

 

[TxGramma]

Re: Stallion Repairs & Trouble Shooting

New issue:
Left fog lamp burned out today. Is there a bulb in there that can be replaced? Nothing in the owners manual. I read a post in another thread from back in June and someone said you need to remove the whole assembly and solder in a bulb!!?? Really?

If this Grandma can do it you can too. Go to your local Auto Zone or equivalent and bring the parts with you. They'll help you find the new connector and give you the right bulb. Bat your eyes and ask him to go through the steps with you. After you get it replaced you'll feel like a million bucks and know you are now able to conquer the WORLD! Go for it, deb!

 

[TxGramma]

Re: Stallion Repairs & Trouble Shooting

The pigtail connector looks like this, deb54

 

[Road Runner]

Re: Stallion Repairs & Trouble Shooting

We hauled the Stallion to Texas hill country to do some riding. Rode 200-300 miles of good roads. Only problem was a complete loss of head and tail lights, returning to camp after dark. Was lucky to have friends on Goldwings to light the way. Thats why we now use a toyhauler.

 

[WildBillH]

Re: Stallion Repairs & Trouble Shooting

Do you know what caused the problem?

 

[Mattel]

Re: Stallion Repairs & Trouble Shooting

Sounds like a fuse issue, did you check them first?