Repairing a R1200GS aux light switch

Discussion in 'GS Boxers' started by Vec, Nov 26, 2015.

  1. Vec

    Vec Has adventure hangover

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    I asked a long while back (http://advrider.com/index.php?threads/2009-gs-adv-aux-light-switch-replacement.1027682/) about the ease in replacing the aux light switch... in the time that passed it went from intermittent to just plain not working. So I ordered a new one, installed it, and set about to seeing what what wrong with the old one.

    [​IMG]
    The top of the switch is held on by a pair of posts on the base of the unit. You can see the lighter gray poking through.

    Since I already had a working one on the bike I didn't care if I ruined this one completely in tearing it apart (but, as you'll see, I actually fixed it).

    [​IMG]
    The base of the top has a spring-loaded plunger that provides the positive detents for the unit.
    [​IMG]
    [​IMG]
    In my case it didn't at all want to spring apart. It was quite content to sit there until I pulled it apart.

    The base had a plunger than matches the cutout in the top of the switch.
    [​IMG]
    [​IMG]
    Which then pushes a tac switch that's buried in the base surrounded by a rubber sleeve.
    [​IMG]
    The problem I was having was that even in the "switched on" position the actual microswitch in the unit wasn't getting pressed down enough to make contact.

    Solution:
    [​IMG]
    I grabbed an 0805 capacitor I had around (no, you can use anything, this was just convenient for me... heck a small blob of epoxy is more than enough)
    [​IMG]
    [​IMG]
    Essentially, all you need to do is make the plunger have a little bit more reach to get to the microswitch on the bottom. Once you get solid contact, you have a fully working switch again.

    [​IMG]

    Problem: Solved! :deal :beer

    And now I have a spare switch I'll likely never need. I guess it's like insurance... another part to never break -- and I'd be able to fix the new one just as easily too. Oh well.
    #1
  2. LowOnFuel

    LowOnFuel In the crapper

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    Nice, thanks for the info.
    #2
  3. ralph1464

    ralph1464 Adventurer

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    The internet is amazing! I had the same problem with my R1200GS ADV switch. Today I solved it as shown above! (My switch is not as dirty as yours, though. LOL!) Thanks for the nice work. Much appreciated.
    #3
    JimVonBaden likes this.
  4. DiabloADV

    DiabloADV Semi-Occasional

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    On Thanksgiving...I am thankful for this thread, as my fog light switch now works!
    #4
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  5. ErikMotoMan

    ErikMotoMan Airbag crash survivor!

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    I'm thankful for the inmates who actually care !
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  6. GlobalriderTrev

    GlobalriderTrev GlobalADVrider Supporter

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    Thanks for posting this Vec. I was wondering how you got your switch out of the housing. I have mine off the main bracket on from the handle bars. However, I haven't figured out how to get the switch free from the outer housing. Any suggestions?? Thanks in advance.
    #6
  7. ultane

    ultane sqeezin the bag

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    Thanks Vec!


    Sent from my iPhone using Tapatalk
    #7
  8. fluff

    fluff n00b

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    I know its years later, but thanks for the tip guys - repaired my switch (which wouldn't stay on) with a piece of guitar pickup, cut out with scissors and snapped into recess in the plastic actuator, didn't even need glue. (tried to add photo but wouldn't upload)

    Attached Files:

    #8
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  9. ultane

    ultane sqeezin the bag

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    I still need to do this to my ‘07 GSA.
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  10. ultane

    ultane sqeezin the bag

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    I haven’t taken my switch apart yet. But in preparation for the repair, I’m wondering how far above the rim of the ‘plunger’ the capacitor extends. I’m probably just going to use a drop of epoxy. How thick is the capacitor?Could it also work if the end of the plunger was just ‘filled up’ with epoxy and had a slight meniscus rising above the rim? Or is the needed amount less than would fill up the end of the plunger?
    #10
  11. GuidoTheKillerPimp

    GuidoTheKillerPimp n00b

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    This is todays task. Pass a wet Irish Sunday
    #11
  12. Limbow

    Limbow Been here awhile

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    You really need to just take it apart and look at it. The pictures above make everything look huge compared to real size. I used a piece of guitar pick and had trouble cutting it small enough! I think you could just use epoxy but I felt better with the pick.
    #12
    ultane likes this.
  13. GS Addict

    GS Addict Pepperfool Supporter

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  14. GuidoTheKillerPimp

    GuidoTheKillerPimp n00b

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    I just did this repair on Sunday. I would say the earlier post showing the guitar plectrum cut and moulded to slightly extend the plunger gives the best indication of what’s required here. However I don’t play the guitar but cut up the tiniest piece of plastic I could find and fixed it to the end of the plunger. Now my piece of plastic extends further than the plectrum leaving me in a spotlights on all the time scenario but I’m happy with that. In fact that was my goal. The area of greatest difficulty for me was fitting the actual thumb switch back on as I had done so much jacking with the screw driver to release the inner switch from the housing that the sides which house the poles had contracted inwards and therefore were not catching the holes on either side of the thumb switch. I rectified this by building a plastic strut from wall to wall within the inner housing. Worked a treat and the thumb switch just clicked into place then.
    I’m a guy who changing a bulb could cause pandemonium around here. The dog hides when I take a screwdriver to the bike.
    Very fixable this. Glad I came across the thread here. My local mechanic just shrugged his shoulders when I asked him to have a look at it.
    Good luck and lock up the dog
    #14
    ultane likes this.