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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: hammick on August 14, 2013, 11:03:00 PM

Title: Bike won't start in gear with the clutch in
Post by: hammick on August 14, 2013, 11:03:00 PM

I am going to troubleshoot this issue tomorrow and want to make sure I understand the procedure

1.  Remove tank and locate the plug for the clutch switch

2.  Check continuity of the clutch switch with the clutch pulled in

3.  If no continuity replace the clutch switch


Is there a way to remove the clutch switch for cleaning without cutting off the plastic?  If I have continuity with the clutch pulled, what is the next step?

Thanks.

Title: Re: Bike won't start in gear with the clutch in
Post by: Scott_ on August 14, 2013, 11:26:08 PM

Quote from: hammick on August 14, 2013, 11:03:00 PM

I am going to troubleshoot this issue tomorrow and want to make sure I understand the procedure

1.  Remove tank and locate the plug for the clutch switch

2.  Check continuity of the clutch switch with the clutch pulled in

3.  If no continuity replace the clutch switch


Is there a way to remove the clutch switch for cleaning without cutting off the plastic?  If I have continuity with the clutch pulled, what is the next step?

Thanks.

If you disconnect the wire under the tank and pull it out, you might be able to unscrew the switch from the lever perch with a small pair of needle nose pliers but I doubt it.

You could try to spray some WD40 or similar into the lever perch at the switch plunger and see if that helps or not, but I'd figure on just replacing the switch and be done with it.

Title: Re: Bike won't start in gear with the clutch in
Post by: hammick on August 15, 2013, 12:34:39 AM

Thanks. It's the switch. I taped the clutch back and pulled out the pin with small needle nose and it would crank in gear. Worked in a lot of WD-40 and so far it still sticks. Pretty sure the spring is corroded or worn out.

Cheap easy fix if you can get a socket on the nut.

Other than this my bike is 100%

Title: Re: Bike won't start in gear with the clutch in
Post by: Scott_ on August 15, 2013, 06:38:10 AM

Quote

Cheap easy fix if you can get a socket on the nut.

If you are surely committed to remove the old one, just cut the wire at the back side of the switch and a socket will then fit. IIRC it's 10mm.

Title: Re: Bike won't start in gear with the clutch in
Post by: hammick on August 15, 2013, 11:23:16 AM

I removed the switch.  Had to cut the wife and cut off the rubber housing.  I used a 7/16" deep well socket to remove it.  My 10mm socket was too small for the nut.

Switch felt gritty and I don't think there is any way to bring one back to life.  I'm buying one on Ebay for $18 shipped.

Thanks for all the help.

ps.:  while I had the tank removed I cleaned everything really good under there and checked my air filter.

Title: Re: Bike won't start in gear with the clutch in
Post by: CRASH on August 15, 2013, 05:21:58 PM

Man, if I had to cut my wife to fix my bike, she would have left me years ago.  :hehehe

Title: Re: Bike won't start in gear with the clutch in
Post by: hammick on August 16, 2013, 10:13:42 AM

He he.  She'll learn her lesson to stay out of my garage. :eek:

Title: Re: Bike won't start in gear with the clutch in
Post by: skidmore on August 22, 2013, 01:47:33 PM

ROFL I had to reread that two times to fully realize you meant "wiRe".....