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No Spark either side till i release the starter button

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    No Spark either side till i release the starter button

    1982 GS 450A.
    I too am working a no spark and voltage loss issue.
    No coils. but not 100% sure what's on it since I've not done that deep. just pulled off the right-side cover to make sure the engine was seized and it's an electronic setup

    My tests results are below, but I only spent an hour so they are incomplete and will have to shelve the bike to work on something else.

    12.67 volts at the battery (new battery but I didn't charge it up. but it will hold easily 13.6x volts when fully charge)
    Lose about 2 volts at the orange and white wires when key is on and not cranking
    Lose about 4 volts total when cranking.

    I took the switch apart and seems I'm missing the metal plate that when you move the toggle to RUN, it bridges the 2 poles.

    I did find the small spring had fallen sideways and it seems this was bridging when in the RUN position making contact before I took the switch apart.
    I fixed that and put the ball bearing so it springs in the detent. Of course now. no bridge so no crank.

    So I will either need to make a repair of find a substitute for the switch to fix that bridge part.

    Now when manually bridging the switch poles with a screwdriver, I see a yellow spark (key on, not cranking) at the plugs.

    Saw someone mentioned this seems to be common.
    Plan is to fix or bypass the switch since if that's not working, nothing will.
    Also made a cable to go from the hotside of the solenoid to both orange/white positive coil leads, but got busy on the switch and never tried the combo of bridging and cranking.

    Best way to approach this when I work on it again in a month?

    Sources for acceptable switches others have used? I could probably find a toggle and rig it in or just replace the entire switch / horn unit.

    Alt
    Last edited by TheAlt; 10-16-2021, 08:46 AM.
    "You are replying to the most modest person you will ever know."

    1982 Suzuki GS 450A
    1980 Honda CM400A
    2002 Honda Relex
    1957 H35 Bonanza

    #2
    Would anyone have a photo or schematic of the switch components?
    Mostly looking for the elements of the red rocker part (springs, ball bearing, contact plate)

    I may have to fabricate one, but since I'm missing they key element that makes the connection to the terminals I'm not quite sure what I'm fabricating, and how it will attach.

    Alt
    "You are replying to the most modest person you will ever know."

    1982 Suzuki GS 450A
    1980 Honda CM400A
    2002 Honda Relex
    1957 H35 Bonanza

    Comment


      #3
      Had mine apart recently to clean. These were the only pics I took. The only thing that helped me reassemble it appeared to be heightened levels of swearing. Hope it helps.



      Rich
      1982 GS 750TZ
      2015 Triumph Tiger 1200

      BikeCliff's / Charging System Sorted / Posting Pics
      Destroy-Rebuild 750T/ Destroy-Rebuild part deux

      Comment


        #4
        Thank you for the photos.
        Looks like I may be missing two parts. There is a spring behind the u shaped contact?

        Does that contact just float on the spring?

        On the big spring, was the order from outside, plastic starter button,copper hat, spring?

        Hope I can make a replacement 667141AD-F685-47DE-ADB0-8D3E126948FC.jpg
        Last edited by TheAlt; 10-16-2021, 08:50 PM.
        "You are replying to the most modest person you will ever know."

        1982 Suzuki GS 450A
        1980 Honda CM400A
        2002 Honda Relex
        1957 H35 Bonanza

        Comment


          #5
          I’ll try to get you some clearer pictures in the morning, it I can do it without taking it all apart.
          Rich
          1982 GS 750TZ
          2015 Triumph Tiger 1200

          BikeCliff's / Charging System Sorted / Posting Pics
          Destroy-Rebuild 750T/ Destroy-Rebuild part deux

          Comment


            #6
            File this under- “No good deed goes unpunished”
            I was only going to take the switch apart to just before point where the bb/ball bearing on top of the spring had to come out. Well, I couldn’t get clear pics that way, so I went all the way in. Hope the pics help. I can’t put that switch back together until I find that bb. I may have to deconstruct some shotgun shells to see if I can find one the right size.









            Rich
            1982 GS 750TZ
            2015 Triumph Tiger 1200

            BikeCliff's / Charging System Sorted / Posting Pics
            Destroy-Rebuild 750T/ Destroy-Rebuild part deux

            Comment


              #7
              Looks like #6 shot size might work. Wish me luck.

              Rich
              1982 GS 750TZ
              2015 Triumph Tiger 1200

              BikeCliff's / Charging System Sorted / Posting Pics
              Destroy-Rebuild 750T/ Destroy-Rebuild part deux

              Comment


                #8
                SUCCESS!

                Back together. I hope to God I never have to take this switch apart again.



                Rich
                1982 GS 750TZ
                2015 Triumph Tiger 1200

                BikeCliff's / Charging System Sorted / Posting Pics
                Destroy-Rebuild 750T/ Destroy-Rebuild part deux

                Comment


                  #9
                  Thanks, those will help greatly.
                  I suspect when I opened it up. the copper plate shot a mile into the yard.
                  Should know better that to work on anything like this other that in a rubber room.
                  Will try to make the contact and find a spring to hold the tension, though my red switch may be broken some. Will tear it apart again and check the neighbors 3-d printer for use

                  Alt
                  "You are replying to the most modest person you will ever know."

                  1982 Suzuki GS 450A
                  1980 Honda CM400A
                  2002 Honda Relex
                  1957 H35 Bonanza

                  Comment


                    #10
                    For disassembly, put the switch in a large zip lock bag and work on it in there

                    Flying parts are contained
                    1978 GS 1000 (since new)
                    1979 GS 1000 (The Fridge, superbike replica project)
                    1978 GS 1000 (parts)
                    1981 GS 850 (anyone want a project?)
                    1981 GPZ 550 (backroad screamer)
                    1970 450 Mk IIID (THUMP!)
                    2007 DRz 400S
                    1999 ATK 490ES
                    1994 DR 350SES

                    Comment


                      #11
                      Originally posted by Big T View Post
                      For disassembly, put the switch in a large zip lock bag and work on it in there

                      Flying parts are contained
                      Yeah, I know better, but was trying to take pics for illustration purposes for the OP. Mine is back together thanks to a #6 410 shotgun shell. Got lots of extra BBs if anyone needs a couple.
                      Last edited by Rich82GS750TZ; 10-17-2021, 06:32 PM.
                      Rich
                      1982 GS 750TZ
                      2015 Triumph Tiger 1200

                      BikeCliff's / Charging System Sorted / Posting Pics
                      Destroy-Rebuild 750T/ Destroy-Rebuild part deux

                      Comment


                        #12
                        Originally posted by Big T View Post
                        For disassembly, put the switch in a large zip lock bag and work on it in there

                        Flying parts are contained
                        I had this same excellent idea. You know when? Right after the switch came apart in my hand over a leaves, dirt and the bike.
                        I should be able to make the parts, just takes some time and patience. Probably can find a suitable spring..

                        Or maybe I will replace the switch with something else that fits close and can be epoxied or affixed in.
                        Alt
                        Alt
                        "You are replying to the most modest person you will ever know."

                        1982 Suzuki GS 450A
                        1980 Honda CM400A
                        2002 Honda Relex
                        1957 H35 Bonanza

                        Comment


                          #13
                          Retractable ballpoint pens contain useful springs.
                          ---- Dave
                          79 GS850N - Might be a trike soon.
                          80 GS850T Single HIF38 S.U. SH775, Tow bar, Pantera II. Gnarly workhorse & daily driver.
                          79 XS650SE - Pragmatic Ratter - goes better than a manky old twin should.
                          92 XJ900F - Fairly Stock, for now.

                          Only a dog knows why a motorcyclist sticks his head out of a car window

                          Comment


                            #14
                            Originally posted by Grimly View Post
                            Retractable ballpoint pens contain useful springs.
                            Yup, right there with you. Hav e some copper pipe I will flatten a and bend for the contact

                            alt
                            "You are replying to the most modest person you will ever know."

                            1982 Suzuki GS 450A
                            1980 Honda CM400A
                            2002 Honda Relex
                            1957 H35 Bonanza

                            Comment


                              #15
                              So once I get the switch rebuilt, what is the issue with the no spark until the starter button is actually released? Is that just a recontact being made?

                              alt
                              "You are replying to the most modest person you will ever know."

                              1982 Suzuki GS 450A
                              1980 Honda CM400A
                              2002 Honda Relex
                              1957 H35 Bonanza

                              Comment

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