Need alil help with small parts/control reassembly.

[JollyRojer]

Sooo i took my controlls off my bent and smashed bars a weekend ago, and it started to get dark as i was doing it, i managed to bag all the parts but 2 of them have me completely stumped after re-assembly of the controls....



i know the left switch goes somewhere on the brake side control but no idea where, i know the middle screw is a tensioning screw for the clutch (i need a new one as the pic shows this one got worked just curious on best place to find one) and the far right is a rubber wedge shaped part with a hole in the bottom that goes about 3/4 of the way threw) any idea on where the switch mounts? as well as the purpose of this small rubber wedge? i havnt gotten the tank or new petcock in so i havnt even tried starting the bike yet just rather get the headaches out of the way before i run into them.

Another question for those of you with aftermarket clipons your GS, what did you do about the brake line? im worried with the 3-4" of extra slack it runs the risk of kinking... not somthing i want to have happen.  Thanks a bunch guys, ive got the majority of tomorrow off and i would love to get this small stuff wrapped up so i can finish paint and repairs on this beast.

quick pic of how the bike sits now...

[Janx101]

the black widget is your clutch sensor on lever .. mounts just inside/along the bar of your light controls .. but depending on year model the location of bolt in point varies?

the right side wedge thingy .. thats the tension locker thingy for your choke slider/lever... goes up under the front of bike side of choke lever .. under a metal plate thingy

making a puzzled face with the silver thingy

pics/diagrams should be avail on the wiki i think?.. for some stuff... sitesearch for diagrams from manual?

[JollyRojer]

ahhh ok, seems weird, i remember the sensor coming from the brake lever side of the bike, and there are 2 connectors on that side for the switch, seems odd for it to be a clutch sensor on the opposite side of the lever but maybe i am misunderstanding you?  ive got a pdf manual i downloaded for free off CF's sticky thread but none of the visual diagrams are there :*( i know what the silver thingy is, its my twisted and pinched clutch cable tension bolt, i am just wondering on a place to pickup a replacement since this one is obviously beyond use wedge makes sense since i remember it coming from that general direction and since the choke doesnt stay in place after being pulled.

[Janx101]

ooops... my bad.. yeah ok .. the brake light sensor thingy .. which i cant picture in my head right now... ive had my left controls apart heaps.. but the right rarely... from vague memory though... that brake sensor .. lays flat on underside? .. under the rubber boot on the base end of brake lever?

wheres Addy and his Encyclopedia WhoosawhatNow!? 

[adidasguy]

Black thing looks like the brake switch for the right hand control.

Yellow: not sure. Need another view of it.

Middle is the clutch cable adjuster for the left hand control where the clutch cable comes off of the perch.

FYI: brake lever doesn't have a rubber boot. Clutch does.

[JollyRojer]

brake switch would make sense i was in dire hopes you would chime in tonight where does it mount? it doesnt seem to have any space inside the actual house and there is a hole in the switch just curious on where on the brake control it mounts. the wegde would make sense as the choke brake since the choke wont stay open unless i actually hold it. as for the boot thing not sure what you mean but any ideas on where to pickup a new clutch cable tension bolt? that one is bent and pinched beyond use...  Thanks for the quick responses guys with the nice weather im itching to ride it

[JollyRojer]

and adidas any thoughts on the brake line being overly long after the bar swap, im worried about kinking...

[adidasguy]

Brake line too long: Can happen with different bars where master cylinder is closer to the front wheel than before. Just tuck the excess and curve it around places so it is safe. There needs to be some slack when the front bounces up and down. You don't want the brake line to snap. later, get a stainless line a couple inches shorter.

Pix #1: Underside of front brake showing switch. It is mounted with one screw.

#2: The clutch perch from the under side (clutch switch is not there). The adjuster for the cable is a very generic part - not at all GS500 or even Suzuki specific. Pretty easy part to come by.

#3: Clutch perch on a bike. The rubber boot covers the adjuster and the end of the clutch cable where it hoes into the perch.


[attachment deleted by admin]

[Janx101]

  speak of the devil!!.. and lo' he appears!! 

[AuburnGSFan]

Can't beat that for clarification.

[JollyRojer]

big thanks! ill try bringing the bolt down to the local shop and see if they can sell me one!