I replaced the stock handlebars on my 2009 GS500f this week with the SM version 2 bars. Everything went well, save for the re-assembly of the left electrical box (choke, horn, blinkers, etc.). I could not figure out exactly how to re-insert the return spring for the choke. I still have the spring, but without it being where it NEEDS to be, I need to hold the choke lever in place, manually (or it reverts back to the 'off' position).

Are there any pictures online (that anyone is aware of) that could illustrate exactly how I fit that spring into the assembly?

It's #29 in this picture:

http://www.bikebandit.com/1998-suzuki-motorcycle-gs500ew-carburetor/o/m6058sch246854

It basically goes around the end of the choke cable that connects to the carbs.

I appreciate the response and link. Odd though, because I didn't really touch anything on that end of the choke cable (nowhere near the carb), and I could have sworn when I was disassembling the assembly for the choke lever, that the spring fell out from that box.

I recently did a handlebar conversion on my GS and had a spring left over. Is this the spring?



If so, it is found here. It is on the underside of the box looking up -



Undo the screw and you will find this little washer under the other washer that secures the cable to the box -



And here is where the spring goes -

Thanks, Twisted! That is exactly what I needed.   

No worries  I felt your pain lol. Nothing worse than having leftovers after a mod and thinking "Oh dear. Where the eff does this go?" Might be a bit of a PITA to get both washers lined back up and the screw in as well. Good luck 

Until I saw your pics, I wasn't even aware of that plastic piece that went around one end of that spring. I went out to the driveway and scoured the ground around where I had done the 'surgery' this past week and, sure enough, there it was. 5 minutes later, i installed that spring and my choke lever was back to operating like it should! Now I need to get back to slowly fingernail-scraping the tank sticker off   

Quote from: Hadrians_Wall on September 26, 2010, 06:06:42 AM
Now I need to get back to slowly fingernail-scraping the tank sticker off   

The idiot sticker on the tank can be removed with a hairdryer or heat gun.

Gently heat the sticker - not too close with a heat gun otherwise you'll bubble the paint. Once heated, tenderly lift one corner with fingernail. Then peel.

Left over residue can be removed with Eucalyptus Oil. Sometimes, also WD40 will remove a small amount of residue.

Michael

Turps on a rag helps get rid of the residue as well