Weird acting gear indicator

[k11pfc]

Tonight, in once again torrential rain, all my problems seem to be in torrential rain, my gear indicator started acting up, showing either 0 or 1 no matter what gear, just after this happened my neutral light started randomly coming on in some gears. Didn't affect anything else, any ideas as to a fix?

[frankenduck]

Water in the GPI switch.

More info here: http://www.motobrick.com/index.php?topic=517.0

[k11pfc]

That's a big old job for someone like me, but if I can get all the info needed to strip back end down I might give it a go. Anyone got a picture of this gear indicator switch? or a photo of position so I can get my head round it?

[k11pfc]

Does this post show a picture of the switch and it's position?

http://www.motobrick.com/index.php?topic=1200.0

[Duc750]

Its probablky about 4 -5 hours work but all pretty easy with the clymer at hand. I'll try and stick a picture up. You need a torque wrench, some brake fluid and a 12mm allen key to go on the torque wrench but other than that its all standard tools

[k11pfc]

A pic would be a great help, thanks. The more help the better, until I get round to it, I'll take neutral light bulb out and pull clutch in to start the bike. It's more annoying than anything else, but in a way good coz I wanted to do a spline lube now I can kill 2 birds with one stone. I'll phone Bahnstormer later for a price on the switch. Loadsa money probably.

[Snowy]

A pic would be a great help, thanks. The more help the better, until I get round to it, I'll take neutral light bulb out and pull clutch in to start the bike. It's more annoying than anything else, but in a way good coz I wanted to do a spline lube now I can kill 2 birds with one stone. I'll phone Bahnstormer later for a price on the switch. Loadsa money probably.

£67.46 from Motorworks

http://www.motorworks.co.uk/vlive/Shop/Parts.php?T=5&NU=15&M=40&Ct=DA&SbCt=BA_15_40_DA_40

[Duc750]

To be fair I'm not sure my poic will be any better than Duck's what I would suggest though is taking lots of pics of cable routing as mine were somewhat lacking !

[Inge K.]

The switch can be opened for drying/cleaning, have a look a bit more than halfway in this rather long thread.

Inge K.

[Duc750]

You know if you are buying new genuine parts its worth trying your local dealer as Motoworks are no cheaper for genuine parts. I bought most of my parts for my recent project from motoworks or motobins and actually the genuine parts I should have bought from the local dealer as they have been excellent and have taken an interest in what I'm dooing even lending me special tools such as the cam shaft locking tool and the specific tool for seating the main seal.

A littlee while ago dealers were told to clear out all the special tools for pre 2001 models but my place just kept them all and put them in a box !

[k11pfc]

I've been informed that it is possible to do this job in situ, if I can get bike up on a lift, anyone know for sure if this is possible?

[Duc750]

I guess that really deopends on what you want to leave in situ !

You have to get the swingarm out from what I can see. I'm not sure you could even get to the bolts without. Unless you're going to do clutch splines as well the bike will stay "free standing" as you will keep the gear box on, that gets you out of removing the battery and abs 2 system. You'll have to re bleed the brakes again though as you'll basically drain the rear system.

[frankenduck]

You'll need to remove the FD and swing arm.  I don't see why you'd need to drain and refill the rear brake.  Just hang the caliper from a piece of string.

[Duc750]

Fair point I can never find the right size bit of string for that though :D

[chrish8846]

When I checked mine there was no disassemble and clean, the outer cover had started to crumble and fall off, I had to get a new switch.

[frankenduck]

When I checked mine there was no disassemble and clean, the outer cover had started to crumble and fall off, I had to get a new switch.

From what I've seen that is generally the case where the simply crumble and fall apart from age.

They live a tough life back there.