Neutral Switch Oil Leaking into Switch

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Neutral Switch Oil Leaking into Switch

New postby MalcTS250 on Sat Feb 17, 2018 2:26 pm

Hi to all,
TS 250M
I have had problems with the neutral light, being difficult to get to light, So I thought I would start at the switch itself first, When the plastic switch cover was removed engine oil came dribbling out of the cover, I would guess the switch cover was full of oil, Can any of you guys please let me know if this is normal, I suspect I have an oil seal problem If this is not normal,
all the oil seals in this engine are the genuine ones that were on the bike when built back in 1975. Not that happy now, It,s looking like an engine strip down may be ?
when I put the switch back together after a quick wipe out, I then had a neutral light again,
Thanks Advice needed
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Re: Neutral Switch Oil Leaking into Switch

New postby MyBad on Sat Feb 17, 2018 3:49 pm

Yes, the switch is in the oil. Very poor design from Suzuki. As soon as the chain derails that switch gets flicked and your now leaking oil till you buy a new one. Racing versions dont have the switch and use a metal cover to block off the aperture.
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Re: Neutral Switch Oil Leaking into Switch

New postby MalcTS250 on Sat Feb 17, 2018 5:47 pm

Many Thanks to you Mybad,
That puts my mind at ease, Because I am always wary about the oil seals in this engine,age wise,
Well it seems I am safe for now then,
Thanks for the quick reply,
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Re: Neutral Switch Oil Leaking into Switch

New postby Butcher on Sun Feb 18, 2018 3:57 am

Behind the cover is the selector drum. There will be an o ring, spring and pin. The pin contacts the terminal on the plastic cover and grounds it when in neutral.

Do you have a multimeter??
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Re: Neutral Switch Oil Leaking into Switch

New postby MalcTS250 on Sun Feb 18, 2018 5:17 pm

Hi to all,
Thanks Butcher, Yes I do own a multi-meter, Yes the neutral switch is working fine now thanks, My initial worry was when I removed the switch cover and engine oil started dribbling out, I thought Ohhhh No, looks like an oil seal gone ,but Mybad has put my mind at ease, there is, a certain amount of oil that collects in the switch which is normal. So Panic Over. For Now.

Thanks for the Response,
Great Forum, By the way.
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Re: Neutral Switch Oil Leaking into Switch

New postby Butcher on Sun Feb 18, 2018 6:59 pm

Lay bike on RHS when doing this. I removed clutch cover yesterday on a TS125ER engine and with bike on LHS, bugger all oil leaked out of the gearbox during this process...
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Re: Neutral Switch Oil Leaking into Switch

New postby kbzx6r on Mon Feb 19, 2018 2:30 pm

I suspect your original problem was poor electrical conductivity at the external neutral switch contact between the wire and switch cover where connected together by the little phillips screw. The act of removing and then replacing the cover (and possibly cleaning the parts during the process) improved the electrical connectivity and fixed your original problem. Mybad was correct that oil inside the black plastic neutral switch cover is normal. There is no seal on the shift drum shaft behind the neutral switch cover, however the cover itself does have an o-ring that prevents the oil behind the cover from leaking out. As long as the cover is not damaged and the o-ring is in good shape and all the little screws are tight the system should work very reliably.
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Re: Neutral Switch Oil Leaking into Switch

New postby MalcTS250 on Mon Feb 19, 2018 3:58 pm

Hi to all,
Yes that is what happened kbzx6r, The neutral light is a bit brighter, and comes on a bit easier with the gear lever, I did notice a tiny piece of gasket material inside the switch cover, I,m amazed the switch contacts can make contact considering they are bathed in engine oil, Oh Well you learn something all the time !

Many Thanks
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Re: Neutral Switch Oil Leaking into Switch

New postby kbzx6r on Mon Feb 19, 2018 6:05 pm

Good catch noticing the piece of gasket material inside the switch cover. That might have become lodged between the springy brass contact on the end of the shift drum and the other contact inside the cover. Oil doesn't pose a problem for electrical conductivity. In fact, whenever you replace bulbs on these old bikes it's a good idea to give the socket a shot of WD-40 before putting the new bulb in. The WD-40 helps prevent corrosion, which DOES cause conductivity issues.
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Re: Neutral Switch Oil Leaking into Switch

New postby Butcher on Mon Feb 19, 2018 11:35 pm

Good find and thanks for the update. Others with same issue might stumble across this thread while searching.

One can lap the plate, removing the grove that can be present. Shining up the brass terminal etc.

Yes it is a wonder how electrical continuity can be made, but it works! I guess the spring helps.
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Re: Neutral Switch Oil Leaking into Switch

New postby MyBad on Tue Feb 20, 2018 5:17 am

A lot of work when a replacement is around $10 and not hard to find.
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Re: Neutral Switch Oil Leaking into Switch

New postby Butcher on Tue Feb 20, 2018 6:35 am

Yep. Need of routine maintenance as well...
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