1980 GS550: "pin" inside switches, handlebar hole?

[mjbraun]

Now that it's warmer, I returned to the garage to work on a 1980 GS550 that I was given (it a million pieces, mind you). I'm putting the pieces back on just to know what's missing but when I put the left and right switch assemblies onto the handlebars the fit was off.

Looking inside the switches, I see a "pin" (see image) that sticks into the area where the handlebar would be, but on the handlebars themselves, I don't see any sort of receptacle. Perhaps the previous owner had replaced the handlebars? Is there a hole on the stock handlebars, do I have to drill one, or is it something else? Either way, it seems that I can't close the switch housings around the handlebars because the pin makes the housing sit at an angle to the bar. Does anyone have any idea what I am missing?

Thanks for any guidance!

[Agemax]

original bars had a locating hole. just file the tab off, like most of us have done

[mjbraun]

Ok, good, I'm not crazy: I had looked for signs of a hole and such in the literature, but to no avail. Dremel, here I come!

And thank you!

[tkent02]

Pliers will break it off a lot easier without the metal partices flying everywhere.

[Thumper88]

Or drill a hole or two...

[tkent02]

Why ?

[Steve]

Personally, I prefer to drill a hole in the bars.

To get a good location, eyeball about where the pin would end up. Remove the switch housing, spray some black paint on the bars. After a few minutes, put the switch housing back in place, clamp it lightly. Move it to a comfortable position, then rotate it around the bars just a bit and slide it back and forth a bit. Remove the housing, you will see nice crosshairs where to drill the hole.

.

[Thumper88]

Why?
Well, here's a video for you all:

https://www.youtube.com/watch?v=ONXcByaGGMU

DISCLAIMER: Has foul language

[Steve]

Why?
Well, here's a video for you all:
https://www.youtube.com/watch?v=ONXcByaGGMU

Sorry, had a hard time trying to watch that.

First few seconds started with language, then there was a VERY shaky camera.

Just could not handle more than 15-20 seconds.

.

[Thumper88]

Ah...sorry, should have put a disclaimer...yes it has some foul language. I just don't understand why someone would not take the time to properly drill a couple holes.

[Nessism]

Drilling keeps the control from rotating out of place. I've busted those tabs off before, but prefer the feeling of a secure control.

[mrbridgeport]

Steve I like that technique for hole location. Gonna use that next time. This video sounds so bad I have to watch it now. I agree with nessism. Drill it.

[Steve]

After you have drilled the holes, it is a simple matter to use some acetone, mineral spirits, carb cleaner, whatever, to clean the fresh paint off the bars.

.