Hello, I'm working on an old 91 TRX200D. I had a crack in the left crankcase cover due to a chain mishap and had to remove it to get it welded. I removed the sator and change switch. The change switch had also suffered some damage as some of the top plastic molding had been crushed inwards and the top was easily separated from the case. The switch pole turned fine and I could feel it making contact when I spun it, so I figured it was just a very simple contact switch. I used some JB Plasticweld epoxy to fill the top gap and fitted it all together and reassembled it into the case cover after I got it back from the welder. After getting it all back onto the motor and filling oil back up, I went to start it up and the red reverse light was on with the trans in neutral. I thought maybe I mess up and got the switch reversed 180 so I drained the oil again and separated the cover enough to rotate the pin and tried that, but that created a situation where the rev light only came on when I jacked up to 4th, so I reverted back to the way I first had it, which engaged smothers into the sloot and had the flat of the post at the top so the keyed indicator points to the N on the case. That seemed to be right. So back to the first problem. The red rev lights when I'm in R and N and turns off as I go up to first and above. The start button will not work in N or any other gear for that matter. If I check the continuity on the Lg/r wire coming from the switch, I get nothing in any gear including N. I do get continuity on the white wire when in either R or N. I believe should be getting it in just R and I should have it for the Lg/r wire only when in N.
It would be great if I could buy a new one, but they seem to be completely unavailable. Does anyone have any idea how to rehab one of these switches and what sort of things to check if I pull this all back out. I've read about doing a bypass toggle switch on the Lg/r wire, but I have a feeling the live circuit for the reverse will block me at the CDI if I can't kill that too. Frankly I don't want to have to mess with rigged up switches to replace the function of the gear switch.
Any suggestion on how to fix switch itself or a source for one would be greatly appreciated. (Honda 35759-HF1-000 SWITCH ASSY., CHANGE )