Left switchgear reassembly - stumped

[exzachtly1]

Took the left switch gear apart to clean it up, was very careful to take it apart in a bag (no lost parts) but am struggling to get it back together. There's one spring that seems to be related to the left/right action of the turn signal and I cannot figure out how to place it!!! Talking about this spring:

It seems like it could go here, especially based on the rust marks I can see on the plastic:

Or does it maybe go here? There is a hole it seems to fit in...

With it in the first position, when I snap the circuitboard back in to place, everything DOES work correctly (including high beams switch) so I think I have everything laid out correctly - I just don't have any resistance on the left/right turn signal. It just kinda slides back and forth too easily. Second spring position seems to gum things up so I don't think it's right.

Any ideas?

Also - I just want to confirm that there should only be a spring + copper contact on ONE SIDE of this switch? It does all appear to function but it seemed a little weird to me that it's only on one side.

 

[bonanzadave]

I believe the first position is correct. Years ago I went down that worm hole and had it all figured out. There were some pretty good pics posted here as well. Unfortunately they came from Photofu(ket and don't exist any more. Let me do some digging. I may have those photos on a old harddrive somewhere......

 

[bonanzadave]

Yes. Your first pic is correct.....

 

[bonanzadave]

Also - I just want to confirm that there should only be a spring + copper contact on ONE SIDE of this switch? It does all appear to function but it seemed a little weird to me that it's only on one side.

Not sure this pic will answer that.....

 

[exzachtly1]

Wellllll dang. Glad to figure out where the spring goes. But now I feel like I'm missing parts... I only have 1 long spring, not two like in your last pic. I also don't have a ball bearing... And I only have a contact on one side of the turn signal switch.

I'll have to give it another shot later but I am 99% confident that I didn't lose anything. Was pretty friggin careful.

 

[exzachtly1]

This is beyond frustrating. Thank you for the pictures, as far as I can tell I am missing these pieces (I can't tell if the one with the ??? is a ball bearing or something?):

So basically I have only one side of the copper contacts on the turn signal switch, and only one long spring, no short spring, no ball bearing(s??).

Now.. I KNOW that I was not clumsy enough to drop ALL of this. No way. I opened it in a baggy and brought everything into the house for cleaning. I could see if I somehow lost one piece, but not all of this... I would have heard something hit the ground or the bike. I scoured my garage floor, kitchen floor, found none of this. This is also not my first rodeo, I had it apart once before and apparently managed to get it together again I'm just not sure how. I don't remember dealing with all of these pieces that time either.

What I've found is that the spring that goes in the back of the turn signal switch is required to operate the high beam up/down. The spring you see that is resting in the channel of the circuit board in this photo is required to have any resistance on the turn signal left/right. It DOES work with only one contact on the turn signal switch. So.. I think if I just had one more spring I'd be good.

But now I have to wonder if I shouldn't be searching for another switch assembly. Blah.

 

[exzachtly1]

Anyone know if the 82 GS300L switch assembly would be the same? Found one on ebay https://www.ebay.com/itm/1982-SUZUK...DLE-HORN-SIGNALS-SWITCH-SWITCHES/223642554688

maybe it could give me the spare parts I need? but I don't think it's a direct replacement since it doesn't have a place for the choke lever like the 650 has.

Also open to a universal solution, but I'd have to figure out how to rework the choke setup probably.

 

[Nessism]

Some more photos in this photo album. Scroll down a little...

https://www.flickr.com/photos/18095073@N08/albums/72157667497870814

 

[Nessism]

Anyone know if the 82 GS300L switch assembly would be the same? Found one on ebay https://www.ebay.com/itm/1982-SUZUK...DLE-HORN-SIGNALS-SWITCH-SWITCHES/223642554688

maybe it could give me the spare parts I need? but I don't think it's a direct replacement since it doesn't have a place for the choke lever like the 650 has.

Does the 300 have self canceling turn signals? Kind of doubt it.

 

[exzachtly1]

Does the 300 have self canceling turn signals? Kind of doubt it.

The 650 is supposed to be self cancelling?

I have always had to push it back to the middle... ever since I bought it, before I messed with anything so I know I didn't screw that up!

And yeah after looking at your photos... someone before me must have lost parts in there. I definitely did not have all that stuff.

 

[bonanzadave]

I shoulda asked earlier. Do your signals self cancel ? My switch pics are from a 82 1100EZ with self canceling signals.

Edit: Never mind......

 

[exzachtly1]

I shoulda asked earlier. Do your signals self cancel ? My switch pics are from a 82 1100EZ with self canceling signals.

Edit: Never mind......

Yeah, the owners manual I have (for a 650 G) does not specify that. This page mentions that the 650E does NOT have self cancelling... https://www.motorcyclespecs.co.za/model/suzu/suzuki_gs650e 81.htm

Regardless I am definitely missing parts. Still not clear if I lost something but I swear I did not drop anything! So I guess it's down to a few options...

1. Work with what I have and try to get a couple of small springs from a place like this https://www.springsfast.com/stock-compression-springs.php... assuming I can figure out the sizes they need to be
2. Try to find a spare unit for parts (so far not looking good)
3. Get something universal like this https://www.denniskirk.com/emgo/universal-left-side-handlebar-switch-46-68734.p218846.prd/218846.sku, but this will require relocation the choke lever somehow. I'll need to look at that to see what's possible.
4. Last resort... buy a NOS unit for $100

 

[Nessism]

On further reflection I don't think your bike has self cancel. From looking at the hand control photos it seems one of the copper contacts is missing along with a ball that the spring pushes on to create a detent. Can that rectangular piece be reversed so the spring would push up, pushing a ball? Is there a detent position in the plastic rail that the ball would slide against?

 

[Gorminrider]

assuming your "L" model has a very similar system....
MY 82 650G does not have self-canceling signals. I don't think any of the 650s do.

My 650G uses the same switch for turn-signals (left-right) and Headlight HI/Lo beam up/down. There is no off-on switch for the headlight.

using the assembly from a different Japanese bike can be tricky...but they pretty much can all be made to work because they mostly all have the same controls and handlebar diameter. I've had a Honda one on this bike when I wanted running lights on a windjammer...

But Id be more interested in keeping the old one where possible. Singular component replacement is often impossibly expensive as you see Ebay can be your friend here...-the whole assembly is what you might find so...while I think those springs are smaller than a ball-point pen spring, if you have a junk pile or even a drawer, such things are often available in other objects....

 

[Gorminrider]

You MIGHT find the same size spring in: the clutch safety switch, the horn button, the brake switch...not saying to destroy these but...they are all cheaper assemblies ...and you might have a junkpile for all I know.

 

[Rich82GS750TZ]

I once found a suitable weight spring inside one of those cheap bic (maybe) mechanical pencils, cut to the proper length, to replace the one in either the clutch or brake lever switch when one of the little suckers decided to liberate itself upon disassembly. The springs in all the click pens in the house were much too heavy in comparison to one in the mechanical pencil.

 

[exzachtly1]

On further reflection I don't think your bike has self cancel. From looking at the hand control photos it seems one of the copper contacts is missing along with a ball that the spring pushes on to create a detent. Can that rectangular piece be reversed so the spring would push up, pushing a ball? Is there a detent position in the plastic rail that the ball would slide against?

Hopefully I'm understanding your question - this picture might help. There are detents on the bottom of the plastic rail, that seem to align with the hole at the bottom of the switch. It looks like if I had a spring and a ball bearing there, that would be the mechanism to "lock" the switch into the 3 positions L/Center/R.

And that spring that goes in the channel (top red line)... I assume it is not a necessity from what I can tell. Probably just there to add a little better "feel" when you're flipping the switch left and right.

If my assumptions are correct then I think the highlighted missing spring and ball bearing are the critical items I'm missing? I can't tell if the other copper contact is needed or not... it does seem to function fine w/o it.

[AND to be clear - I only have one spring... I'm just moving it around for the photos]

assuming your "L" model has a very similar system....
MY 82 650G does not have self-canceling signals. I don't think any of the 650s do.

My 650G uses the same switch for turn-signals (left-right) and Headlight HI/Lo beam up/down. There is no off-on switch for the headlight.

using the assembly from a different Japanese bike can be tricky...but they pretty much can all be made to work because they mostly all have the same controls and handlebar diameter. I've had a Honda one on this bike when I wanted running lights on a windjammer...

But Id be more interested in keeping the old one where possible. Singular component replacement is often impossibly expensive as you see Ebay can be your friend here...-the whole assembly is what you might find so...while I think those springs are smaller than a ball-point pen spring, if you have a junk pile or even a drawer, such things are often available in other objects....

Yep, that's exactly how mine works.

You MIGHT find the same size spring in: the clutch safety switch, the horn button, the brake switch...not saying to destroy these but...they are all cheaper assemblies ...and you might have a junkpile for all I know.

No luck on the junkpile items. I found a decent looking assortment at home depot that I might try... https://www.homedepot.com/p/Everbilt-Spring-Assortment-Kit-84-Pack-13554/203133714 but that doesn't solve the missing ball bearing. Amazon has some assortments of ball bearings. https://www.amazon.com/Hilitchi-Metric-Precision-Bearing-Assortment/dp/B07VNSDLWS/ref=sr_1_13... but like many of these items, if I buy that then I will probably end up with 509 ball bearings that I'll never need haha. But could be a good thing to have around the house

 

[exzachtly1]

Seems the spring and ball bearing need to be in the neighborhood of 3.5-4 mm diameter. Gonna see what I can find on good old amazon and hopefully reconstruct this thing.

 

[Nessism]

Balls typically are imperial dimensions.

 

[Rijko]

Seems the spring and ball bearing need to be in the neighborhood of 3.5-4 mm diameter. Gonna see what I can find on good old amazon and hopefully reconstruct this thing.

Last time i needed a ball bearing for that i found a nice supply in the headset of an old bicycle