[EgnerFamilyGuy]

I posted about this once before. I followed the directions in the I want a louder horn article exactly as they were written. Everything was exactly fine. However the horn stopped working maybe one month after installation. There was some green dust on the relay so I replaced it.

The new relay blew only three days after installation- right after a huge rain storm. I thought water caused the first one to blow so this time I wrapped the whole thing with electrical tape. I started half way up the four wires and taped completely down to the relay itself, thinking this would waterproof it. I think it actually made the water worse. There is a lot of corrosion on this relay. I posted a pic so that you may be able to identify this as water damage for sure.

My question is this: how do I water-proof the relay? I ride rain or shine, so I have got to find a solution to this problem.

[FrugalNinja250]

You can buy a waterproof relay like this off ebay: http://cgi.ebay.com/ebaymotors/waterproof-relay-and-connector-12-volt-Ford-truck-_W0QQcmdZViewItemQQhashZitem439fb69d5eQQitemZ290442354014QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

or better yet, go scouting at a wrecking yard for relays mounted in the passenger compartment. They all have similar looks (at least four wires, boxy, etc). GM products always use a relay to switch on the cooling fan, that would be a good candidate. Be sure to put some silicone grease on the rubber seal when installing the connector, and always mount the relay with the terminals facing downward.

[EgnerFamilyGuy]

My uncle works at a wrecking yard and has for years, this shouldn't be a problem. I however am not much of a gear-head, what do I ask him for specifically? Oh, and THANKS!!

[mattwood1221]

And had water problems. http://forums.ninja250.org/viewtopic.php?p=798093#798093

I ended up putting a coat of five minute epoxy around the seam of the relay, and it has worked fine!

[EgnerFamilyGuy]

[mattwood1221]

It comes right apart, and clicks back together if needed.

[EgnerFamilyGuy]

ok i got it, quite corroded inside as to be expected. I believe I'll buy one more radio shack relay and try to epoxy the seam. if this does nothing for me then i'll get a waterproof one. do i need to water proof the wire connections and prongs as well as the seam? Also do you think silicone could be used in place of epoxy?

[mattwood1221]

with the connections and prongs. Silicone probably could be used, but I think epoxy would be better due to it's hardness compared to silicone. I'd be afraid of the silicone cracking or coming off from vibration or rubbing.

[DL13210]

I installed my horn relay, terminals facing downwards not sideways. I applied grease in terminal connections, no corrosion in terminals so far as of Feb 2010

http://forums.ninja250.org/viewtopic.php?t=80142&start=0&postdays=&postorder=&highlight=

http://forums.ninja250.org/viewtopic.php?p=793404#793404

[FrugalNinja250]

Just ask for a GM radiator fan relay, or a Ford, or (etc). Fan motors draw a lot of amps, just like the horn, so a fan relay should handle it ok. The main thing is to get one of the weatherpak relays (with the silicone gasket around the wiring connector) along with the terminal and enough wire to make your connections. Also, make a note of what the relay came off of so that in the future you can replace it easily.

[EgnerFamilyGuy]

I just wonder how you took the original wires from your horn to your relay beside the fuse box? just a patch wire? I am thinking about moving my relay as it is up against the radiator as is.

[mattwood1221]

I wired mine right out of the junction box, and put the relay right by it. If I remember correctly, I cut the horn wire, stripped the insulation off of both ends and the wire to the fuse box, and somehow held them all together while soldering them together, and covered with heat shrink. This picture is pointing to the main fuse, but it also shows my wiring job.

[woot]