GPI Problems....

[IhmeJanneFIN]

I pulled my neutral / gear indicator switch and it has mounting holes 50mm apart and 36mm diameter where it inserts into the case.

There may be many older (early to mid 80's suzuki's) that had gear indicators with interchangeable neutral / gear indicator switches... I'm doing some research now...

It looks like the GS 1100/1150 part will bolt on (thanks Astro) but I'd like to check GS 550/650/750/850 parts too.

At least a neutral switch from 1982 GS 650 wont fit. It's too small.. Bought it and allready changed the blug in it, and not until then decided to check if it fitts, what it doesnt, so no return possibility anymore

[GSXFJim]

At least a neutral switch from 1982 GS 650 wont fit. It's too small.. Bought it and allready changed the blug in it, and not until then decided to check if it fitts, what it doesnt, so no return possibility anymore

The P/N your looking for is 37720-24A01

So it is sorry about that.

I'd love to see a nixie tube version but I don't think a nixie would hold up well to all the vibration.

No worries.. if you interested in one let me know...

[IhmeJanneFIN]

The P/N your looking for is 37720-24A01

I have that smaller switch, (37720-45100 probably), so is there any way to add plastic around it to make its diameter 36mm. It's diameter is now 26mm, so +5mm all around the whole thing. My question is, could I do some plastic welding to add diameter or glue some sort of plastic/metal ring on it, or is this a doomed idea..

Ps. Don't have budget to buy a new one (~60$) and haven't found a cheap right one in ebay.

[BareKat]

That would be a terrible idea IhmeJanneFIN. It would never work!

[05RedKat600]

I have that smaller switch, (37720-45100 probably), so is there any way to add plastic around it to make its diameter 36mm. It's diameter is now 26mm, so +5mm all around the whole thing. My question is, could I do some plastic welding to add diameter or glue some sort of plastic/metal ring on it, or is this a doomed idea..

Ps. Don't have budget to buy a new one (~60$) and haven't found a cheap right one in ebay.

Doomed idea. Gotta buy the right part for this one.

[GSXFJim]

I have that smaller switch, (37720-45100 probably), so is there any way to add plastic around it to make its diameter 36mm. It's diameter is now 26mm, so +5mm all around the whole thing. My question is, could I do some plastic welding to add diameter or glue some sort of plastic/metal ring on it, or is this a doomed idea..

Ps. Don't have budget to buy a new one (~60$) and haven't found a cheap right one in ebay.

Call it a loss, put it on ebay and try and get some of your $ back then purchase the correct part.

[IhmeJanneFIN]

Dammit!

Well, gotta keep searching for the right part..

[GSXFJim]

Dammit!

Well, gotta keep searching for the right part..

Again.. The P/N your looking for is 37720-24A01

very few pop up on ebay.. just search a few sites to find the best deal and buy it.

[IhmeJanneFIN]

So, I bought the wrong neutral switch to my bike (not the P/N 37720-24A01), it was too small and was told it cannot be fitted to my bike (-94 Suzuki GSX 750 F, or Katana in some places).
Well, we have this thing called "SISU" back here in Finland. It means roughly transferred that you have guts, but in much much more quantity. (it might also be stupidity, who knows )
Anyhow, this is how I made myself a spacer to fit my "wrong" neutral switch..

On the left, neutral switch from a -82 GS650, and right one stock neutral switch from -94 GSX 750 F..



A bit small as you can see, gotta make a spacer for it..



Material is 2mm thick aluminium, might be too thin though, time will tell..



Rough sketch..



And we have a hole where to fit the switch..



Outline sketch..



Rough cut.. (mounting holes didn't hit just right..)



On the block..



Almost finished..



And it fits



But still needed some modification to be done..




How a bout that, seems to fit ok



Some heat resistant siliconeglue..



And vóila..




I have now put piece on the bike with some more of that heat resistant siliconeglue inbetween the block and spacer, but haven't let oil touch it yeat. Gonna let it dry overnight for sure before doing that. I also tested with ohmmeter and every gear is found
Tomorrow I will see if it holds oil in and if it does, time will tell how long (hopefully till end of wold )

What do you think guys? Pure madness/stupidity or something else?

[Kreylyn]

If it works like that on your final test, go back and make a simple additional adjustment.

Use 2 "spacers" on the exposed thread sections to help prevent over tighting and cracking/breaking the little bit of plastic you have for the puck. You want the washer to clamp the puck, but your current setup leaves it very open to easily vibrating loose, or cracking/breaking stuff. (similiar spacers are used on the coils for the bike btw... )

Krey

[Wild-Bill]

Nicely done! I would have thought that you wouldn't get contact with the added spacer in there but you said it seems to work so...

[Kreylyn]

Oh, one other thing... how are you going to make a good oil seal on that location? The OEM part has the O-ring that seats inside, but... I guess you will need to make a gasket. Not sure how the surface is on that for that point as it wasn't designed originally for the gasket but in the pic it looks clean and flat....

Krey

[IhmeJanneFIN]

If it works like that on your final test, go back and make a simple additional adjustment.

Use 2 "spacers" on the exposed thread sections to help prevent over tighting and cracking/breaking the little bit of plastic you have for the puck. You want the washer to clamp the puck, but your current setup leaves it very open to easily vibrating loose, or cracking/breaking stuff. (similiar spacers are used on the coils for the bike btw... )

Krey

That's great idea, but I got another kind of idea how to make sure it stays on.. Hopefully I have enough material left..

Oh, one other thing... how are you going to make a good oil seal on that location? The OEM part has the O-ring that seats inside, but... I guess you will need to make a gasket. Not sure how the surface is on that for that point as it wasn't designed originally for the gasket but in the pic it looks clean and flat....

Krey

There was a small section of flat surface around the whole thing and I also put a lot of silicone in the groove where o-ring goes, so when I putted the spacer on it touched quite much the spacer which then seales it, hopefully..

Originally Posted by Wild-Bill
Nicely done! I would have thought that you wouldn't get contact with the added spacer in there but you said it seems to work so...

I just lenghtened the spring a little bit.. Contacts are only about 2mm more outside than with stock neutral switch..

[BareKat]

IhmeJanneFIN, for some reason I thought of this cartoon when I was admiring your handy work.

[05RedKat600]

Has it been confirmed working yet? I'm concerned about the different diameters of the two parts, and how the ball will contact the pads, if at all. Keep us posted.