1983 R100RS Rebuild: Diagnose and Replace Failed Neutral Switch

When I bought the bike in January 2015, the neutral bulb didn’t light and the starter motor wouldn’t work unless I pulled the clutch. I need to figure out what is going wrong in the starter circuit and the neutral switch. I wrote up the work I did here including how I diagnosed that the neutral switch failed and how to replace it:
This write-up makes use of some short videos to show what I do. I’m experimenting with how to use video clips to explain things better than just pictures and text can.
There is a longer video at the beginning in which I explain how I use the Haynes wiring diagram and Bob Fleischer’s material to figure out how the neutral and clutch switches work in the starter switch circuit.
I’ve heard fellow Airheads tell me electricity is confusing and a mystery. So I thought maybe showing how I try and figure out how components work from the wiring diagram when I have a problem may be of some value.  Here is a direct link to that video.

Here are the other short videos I shot that are included in the write-up.

Here are a few pictures from the write-up.

Neutral Light Not Lit

Neutral Light Not Lit

Printed Circuit Contacts for Neutral Switch

Printed Circuit Contacts for Neutral Switch

Neutral Bulb Pins on Printed Circuit

Neutral Bulb Pins on Printed Circuit

Neutral Switch with Grunge

Neutral Switch with Grunge

Degreased Bottom of Transmission and Engine Oil  Pan

Degreased Bottom of Transmission and Engine Oil Pan

Prying Out Center Engine Mount Spacer

Prying Out Center Engine Mount Spacer

Old Switch Ready to Remove

Old Switch Ready to Remove

New Neutral Switch and New Washer/Spacer

New Neutral Switch and New Washer/Spacer

New Neutral Switch with Plast-Aid Applied to Prevent Leaks

New Neutral Switch with Plast-Aid Applied to Prevent Leaks

Neutral Light Works Now :-)

Neutral Light Works 🙂

Leave a Reply

Your email address will not be published. Required fields are marked *