Kenessex thank you for picking up on my clues and symptoms. I have taken apart the left switch assembly a couple times and everything looks really clean inside, but the colors of the wires dont match up with the wiring diagram, (no spiderwebs or anything and wires look healthy) But when it gets to the headlight cavity everything is a mess with the wiring in there. I have adjusted the screw on the back of the horn as well and like i said it only does a slight vibration...UPDATE... when I turn the key off right before it is in the OFF position a little tiny beep comes out of the horn, but if the bike was running you wouldnt be able to hear it.You guys seem to have missed the little tidbit of there is a constant 6V to the horn even when the horn button is not pressed. The other little clue he presented is that the horn and wires are hot when he is running the bike. The horn and wires are not designed to have constant voltage with no work being done, i.e. the horn not vibrating. So there is yet another problem, as in either the horn button is stuffed or there is a short in the system. Either way, take the left switch assembly apart and look for the wiring problem. Besides the adjuster screw on the back of the horn, quite often there is a build up of rust and insects in the horn. Try giving it a few whacks with a screwdriver handle while it is activated and see if it starts squawking. I generally use a #3 phillips from Snap-on with the black triangular handle. It has just a little more heft than the #2.
Its simpler than that I believe- the horn should have power whenever the key is on and the battery is alive. The horn button switches the ground(negative). So you will read positive six volts at the horn even without pressing the button. But there should be no current flow(and heat buildup) unless the button is pushed. So the button is shorted to ground or the wiring is wrong or the wire is shorted to ground.The short is not in the horn. I suspect it is in the mess in the headlight shell. The horn should not be getting voltage without the button being pushed. It could just be that the wrong wires are connected in the headlight. Whacking the horn is to dislodge any insects, dirt or rust which are preventing the diaphragm from vibrating as it should. Are you using the handle from a #3 Phillips? It should be pretty easy to identify the wires from the horn button and from the horn and see if they are properly connected in the headlight bucket. Check it against a wiring diagram, it is a pretty simple circuit.
