Author Topic: K75 Clutch Switch Intact Removal  (Read 5503 times)

Offline Motorhobo

  • +25 years of K75
  • ^ Quintessential Motobricker
  • Posts: 1530
K75 Clutch Switch Intact Removal
« on: October 23, 2017, 07:10:40 AM »
Looking here:

http://www.motobrick.com/index.php/topic,662.msg1974.html#msg1974

I need to remove that switch intact from my parts bike to install it on my daily rider.

First -- can someone confirm that this is the part? I didn't see any aftermarket supplier and this part is now +$45 at the dealer, same price new on eBay and Euro Motoelectrics. Beemer Boneyard is out of used stock on this switch.




Second, Inge says this same switch is used elsewhere: see http://www.motobrick.com/index.php/topic,6301.msg42208.html#msg42208. Maybe it's easier to get off the right grip, anyone used it from there as clutch switch.

Any input appreciated. I've been starting the bike in neutral for a couple weeks but that's a pain in the ass and I want it to work like it's supposed to but I'm too 'value-conscious' (i.e. cheap) to buy a new one and that's why I have a parts bike anyway.
1994/1995 K75 ABS Frankenbike: original engine 136k miles, frame from Gary Weaver (RIP), 173k miles -- Current Odometer: 198k miles
1994 K75 since 2013, 82,000 mi (19k mine) w/California Sidecar Friendship II Sidecar & Black Lab 'Miss B' - RIP

Past: 1974 Honda 550/4 (first bike), 1994 K75 (sold), 1995 K75 ABS (parts bike), Sidecar Dog & Best Bud 'Bo' - RIP

Offline rbm

  • ^ Quintessential Motobricker
  • Posts: 2308
Re: K75 Clutch Switch Intact Removal
« Reply #1 on: October 23, 2017, 06:15:38 PM »
The part you've shown is the correct part for the clutch switch.  It is the same part used on early K-bikes for the rear brake switch and as the choke indicator switch.  It uses an M8 x .75 thread to mount and a standard 10mm hex wrench can easily be used to unscrew it from the clutch perch. I usually find enough of the hex part to engage the open part of the wrench.  Once I've given it about 180* of turn, the rest is just unthreading it by hand.  No problems.


Seeing that your bikes are mid-90 models, neither will have the older brake or choke switches installed.  BMW stopped  using this switch as a rear brake switch fairly early, replacing it with a microswitch just behind the footpeg plate.
  • Regards, Robert
Toronto, Ontario

1987 K75 - Build Blog @http://k75retro.blogspot.ca/

Offline Motorhobo

  • +25 years of K75
  • ^ Quintessential Motobricker
  • Posts: 1530
Re: K75 Clutch Switch Intact Removal
« Reply #2 on: October 26, 2017, 09:29:04 AM »
No problems.

Hmm...wondering whether we're talking about the same bike. Here are two pics of my spare clutch perch assembly.

The first pic is the intact perch with the switch in the recess and the clutch cable adjustment screw installed, which shows how little room you have to get a wrench in there without pulling out the clutch cable and removing the adjustment screw.

The second shows how little room you have even with the entire perch assembly off the bike. Here, removed the adjustment screw and tried to pull back the rubber jacket to get more free space to get a wrench in there. Tip -- don't do that unless you want to break the switch, because the boot won't come off without breaking off the solder joints. This is a standard 10mm Crescent wrench. No way that's getting any purchase on that hex screw. The only thing that might get in there is a 10mm flare wrench, I'm going to get one and try it out. The other thing that might work is a 10 mm deep-socket but I'd have to cut a slot through it to make room for the cable.

Bottom line -- there has to be a special tool for this. None of my needlenose even got close to gripping that screw.

Now I have to resolder those joints...or order another switch for $39.99...
1994/1995 K75 ABS Frankenbike: original engine 136k miles, frame from Gary Weaver (RIP), 173k miles -- Current Odometer: 198k miles
1994 K75 since 2013, 82,000 mi (19k mine) w/California Sidecar Friendship II Sidecar & Black Lab 'Miss B' - RIP

Past: 1974 Honda 550/4 (first bike), 1994 K75 (sold), 1995 K75 ABS (parts bike), Sidecar Dog & Best Bud 'Bo' - RIP

Offline Motorhobo

  • +25 years of K75
  • ^ Quintessential Motobricker
  • Posts: 1530
Re: K75 Clutch Switch Intact Removal
« Reply #3 on: November 06, 2017, 10:25:56 AM »
The part you've shown is the correct part for the clutch switch.  It is the same part used on early K-bikes for the rear brake switch and as the choke indicator switch.  It uses an M8 x .75 thread to mount and a standard 10mm hex wrench can easily be used to unscrew it from the clutch perch. I usually find enough of the hex part to engage the open part of the wrench.  Once I've given it about 180* of turn, the rest is just unthreading it by hand.  No problems.


Seeing that your bikes are mid-90 models, neither will have the older brake or choke switches installed.  BMW stopped  using this switch as a rear brake switch fairly early, replacing it with a microswitch just behind the footpeg plate.

Following up here...

First, on my 1994 and 1995 K75 that's not a 10mm nut, it's 11 mm. Second, on my bikes there's no way to get a standard hex wrench in there, whether the clutch perch is installed on the bike or not. I have the unattached perch from my parts bike on my workbench, and no 11mm open-ended wrench -- not even an 11mm flare -- will go in there with enough clearance to get any purchase on the nut. It's even worse with the perch installed on the bars, because with my RT bars the curvature of the bar blocks access to the recess where the switch connector lives.

I tried turning the rubber jacket with needlenose in the hope that the bond between the jacket and the connector would be strong enough to crack the nut so it would spin. Tip: don't do that. It's not: jacket will just rotate and the nut will stay seated.

I tried making a tool out of an 11mm wrench, see the image marked 'FAIL'. Nice try, but the recess still didn't have enough clearance to accommodate the bend in the wrench.

This worked:

1. Get a Craftsman 11mm 1/4 drive true deep socket from Sears for under $5. My local small-town family Sears franchise store had it, didn't have to drive all the way to a Sears retail store. You need a deep socket because the piece has to slip down over the rubber jacket covering the connector, and a standard socket isn't long enough. You need the 1/4 drive because wall of the the 3/8 drive socket is too thick to get down in that recess where the nut is.

2. Get your grinder with cutting wheel and cut off the drive end, leaving maybe 1 1/2 inches of the hollow socket to work with.

3. Cut a channel for the switch cable to slip through.

4. Cut a slot in the top. I cut it off center to get a flat screwdriver through, but it turns out you just need the slots. Or, if you have a drill press drill a couple holes through the whole piece.

5. Lubricate the jacket so the tool slides down over it onto the nut and tighten or loosen as needed.

You can turn the tool by putting a screwdriver blade into the slot (or a small phillips into hole, if you've drilled them) and applying torque. It doesn't take much to crack the nut off its seat, then it just turns by hand until it comes out. For tightening, it's not supposed to get a lot of torque, maybe a quarter or half turn once the nut makes contact with the seat.

If anyone else has pulled/installed this switch by other more simple means, more power to you. But if  you want to remove that switch without removing the perch, disconnecting the clutch cable or dinking with needlenose pliers or wrenches that don't fit, spending the $5, making 5 minutes of cuts with your cutting wheel and making the right tool for the job as described here is a pretty good option.


1994/1995 K75 ABS Frankenbike: original engine 136k miles, frame from Gary Weaver (RIP), 173k miles -- Current Odometer: 198k miles
1994 K75 since 2013, 82,000 mi (19k mine) w/California Sidecar Friendship II Sidecar & Black Lab 'Miss B' - RIP

Past: 1974 Honda 550/4 (first bike), 1994 K75 (sold), 1995 K75 ABS (parts bike), Sidecar Dog & Best Bud 'Bo' - RIP

Offline stokester

  • ^ SuperNatural Motobricker
  • Posts: 847
Re: K75 Clutch Switch Intact Removal
« Reply #4 on: November 06, 2017, 07:33:44 PM »
Great info and a creative solution.


My K75 never started unless it was in neutral, pulling in the clutch had no effect.  I never thought much about it until I went to the Klassic K Kampout and spoke with some other brick owners to find out that it should start with the clutch pulled in. 


I was able to remove my defective switch with a pliers but had to install the new one by hand because of the location and center cable.


Now to go get a cheap socket and do some grinding to make a tool.
  • Yorktown Virginia
  • '94 K75S Dakar Yellow - '93 K75S Seiden Blau - '91 R100RT Bermuda Blue- '78 R100S Smoke Red

Tags: