Starter button repair

[eddard]

My 30 year old GS850GL (that I bought new) finally had a breakage that caused me to have to "push start" it.

I was leaving Walmart, pushed the start button and my thumb slid off. The button popped out......like completely off the switch pod. I looked down to the pavement and saw a small copper spring and the remains of the button. I retrieved these parts and push started to get home.

After some internet searching and researching, I found almost nothing to show me what the disassembled switch looked like, even in parts fische photos. So I disassembled the switch for investigation. Though there was obviously another piece (lost in the Walmart parking lot), I had not a clue what it looked like. After some examination and head scratching, I came up with an idea. Rather than order the entire right handlebar switch pod (which is $130), I used a Barnes .30 caliber pure copper bullet to form what I "thought" should work as a replacement switch contact using my 3-in-1 hobby lathe.

I first super glued the broken button pieces together. It took about 2 hours of fit trial and error, but it works!

[chuck hahn]

That i take it was the hat shaped copper cup thing.

[eddard]

I have to take your word for that, Chuck. The one I made ended up looking like a very small watch battery. It was .10" thick, had a shoulder of about .3" (the spring presses against that shoulder), and a protrusion of .250" that makes contact with the circuit board of the switch. I should have taken a picture of it.

[razor02097]

Chuck is right. There was a copper "hat" that goes on the button and then the spring. The spring conducts one terminal to the hat then when you push the button the hat touches the other contact on the board.

Look at the bottom right of this picture to see all 3 parts.

[eddard]

I done good then. The part I made without knowing what it should look like, is nearly identical to the original in your photo.

[chuck hahn]

And what about the picture of the home made "hat"??

[eddard]

I'm not going to disassemble the switch for picture taking!

[chuck hahn]

I will take a look in my stash boxes and see if I have an OEM one if you would like...if i do you can have it.

[eddard]

I appreciate that offer very much, but the home made one is working just fine. Perhaps another forum member needs it more.

You don't happen to have the plastic button do you? As I stated, I super glued mine together, and it's holding so far, but it has me worried.

When I did the repair, I figured that if the button itself re-failed, I could make one out of UHMWP or even aluminum. I see no problem with the button being electrically conductive.

[chuck hahn]

If the super glue fails again you should use ABS repair glue. Also do a search for a thread called PROJECT WINDJAMMER..You can use acetone and ABS shavings to perform AB S plastic welding..Its like it a new part when your done. I will take a look around for what I have..but i dont think theres a button.

[argonsagas]

Compliments on the inventiveness!




My 1100G has a copper-plated BB in the ignition switch.


same reason.....

[Guest]

I had the same problem with the start button. Came out to the bike after work and went to push the button and there was no button. But I found the remains of the button, the spring and the copper hat part, fiddled around with them until I figured out what order they had to be and was able to push it to start. Put all the parts in my pocket and headed home.

But my solution was a lot less inventive...pulled another start button off the parts bike!! But now I know another way to fix this problem in the future. Thanks!

[chuck hahn]

No spare buttons...sorry.

[Watsup300]

buttons found?

I just recently had my button on my gs450 break i fixed it as well with superglue but feel it will fail eventually. I found this thread there is a man in there claiming to be able to make them at a good price here http://www.thegsresources.com/_forum...starter+button

also in that thread there is a website selling buttons for a gs1100e horn for 6 bucks + 6 shipping they seem like they should fit a few different models. I plan on buying one ill let you know how it works out. http://www.alpha-sports.com/suzuki_parts.htm search left handle switch for a 1982 gs1100E,ES and its item #24