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sidecar paul

sidecar paul
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A used clutch lever assembly arrived, from e-bay, in today's post. Well, for 9 quid it'll be a useful spare and I fancy doing a blue set for my blue solo.

Now, have you ever tried to remove the clutch switch without destroying it?
This one was pretty tight and after soaking with WD40, flat pliers still didn't make an impression on it.

The switch hexagon is 11mm AF and there's no way a normal box spanner (even if I had one!) will go over the connector to reach the hex.

My solution was to cut a short length of tube, about ½" bore and flatten the end in a vice to a bit less than 11mm. I then filed the end to make a two sided spanner.

A 'spanner' to undo the handlebar clutch switch Sam_0617

This then slipped over the connector, along the cable to reach the switch.
I had to grip the tube in the vice to get enough grip to undo the switch so maybe I'll drill a hole for a tommy bar in case I ever need to remove a switch while it's still on the bike.

A 'spanner' to undo the handlebar clutch switch Sam_0618

There may be a proper tool for doing this, but if you're stuck this tool is pretty easy to make and it may save a few curses.

Cheers,
Paul.


__________________________________________________
'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

2Back to top Go down   A 'spanner' to undo the handlebar clutch switch Empty wrench on Wed Jul 10, 2013 6:44 pm

ibjman

ibjman
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That IS a very thoughtful solution. Particularly that you gripped it on 2 opposite sides.
Using an open end wrench will ruin the switch almost every time. but I see you can't even get that in there. When I put my new switch(s) in my rs, I used anti seize and only barely tightened them just enough to prevent them from vibrating loose.
GREAT Job!


Regards, Ibj...



Last edited by ibjman on Wed Jul 10, 2013 6:54 pm; edited 1 time in total

    

sidecar paul

sidecar paul
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@ibjman wrote:11mm tubing flare nut wrench, about $12
A 'spanner' to undo the handlebar clutch switch Wrench10

That'll never get into the recess.

Paul.


__________________________________________________
'84 K100RS (0014643) (owned since '85), 86 K100RS (0018891) with Martello sidecar (built as an outfit in '88),
'51 Vincent (since '67),'72 Montesa Cota (from new), '87 Honda RS125R NF4 (bought 2015) 
....No CARS never ever!
    

4Back to top Go down   A 'spanner' to undo the handlebar clutch switch Empty You ARE quick Paul on Wed Jul 10, 2013 6:55 pm

ibjman

ibjman
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You're quick, paul.........you corrected me faster than I could post a corrected edit.

    

charlie99

charlie99
VIP
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top job scp .... that one sliped by me for one ...


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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OA 'spanner' to undo the handlebar clutch switch Au-log10

"redframe" rs "bitsa"  with many contributions from the k100 community ,,with many thanks
    

6Back to top Go down   A 'spanner' to undo the handlebar clutch switch Empty Another Solution on Fri Nov 15, 2013 4:37 pm

ibjman

ibjman
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If you don't mind a bit of a hassle, this can be done with (somewhat) standard tools.

I just changed one on my 1998 RT.....same set up....switch is buried deep into the recess in the casting.

I chose to disconnect the switch harness lead at it's harness plug connector and remove the individual wire spades from the plastic connector. It takes a special probe to release the wire spades from the plastic connector and it takes a bit of patience to get them out without damaging the retaining tabs that hold them secure in the connector.
  Once the individual wires are free from the plastic end, I just slip a 3/8" drive 11mm deep socket over the wires and thread it down the wire to the switch. Install the deep socket over the switch and turn it loose with a pair of vice grips.

I think it's a toss up as to which might be easier for some folks. Making the suggested tool above or extracting the wire spades.
 Just an additional point of view.
Regards, Ibjman

    

Guest

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This is a job for an 11mm box spanner - I have at least two in my garage. There is also another choice it is a full hex spanner with a hole through the end and a right angle. Not sure what the name is but in 25 years of Aircraft work I had never seen one before. I left the UK and came to France and you can buy them everywhere. I'll try and find a picture.

    

Guest

avatar
Guest
A 'spanner' to undo the handlebar clutch switch Spanner

This is the beast. They come in a set with 8, 10, 11, 13, and 17mm. You can also buy individual one of all the sizes in between.
This one is a bi-hex, but I only buy the hex ones. There is a hex in each end and the one in the short bit has a hole all the way through for taking nuts off long studs.

    

RicK G

RicK G
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VIP
The French have strange tools because they make strange cars.


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."  from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

ibjman

ibjman
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A 'spanner' to undo the handlebar clutch switch Box_sp10

    

RicK G

RicK G
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VIP


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."  from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

TacKler

TacKler
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@RicK G wrote:The French have strange tools because they make strange cars.
And they make aeroplanes too........... That's why I fly Boeing. 

I wonder why Zee Germans don't make aeroplanes? scratch


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Red 1991 K75S
    

RicK G

RicK G
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There was something about not making them in the surender deal at the end of WW2 or at least I think it was WW2, it may have only been WW1.  Thw WW1 deal was what turned BMW to making motorcycles and not producing anymore planes


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats."  from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

14Back to top Go down   A 'spanner' to undo the handlebar clutch switch Empty meet the fokkers on Sun Nov 17, 2013 6:32 am

colinijohnson

colinijohnson
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Ze Fokkers started in the Fatherland - the original flying bricks!



Last edited by colinijohnson on Sun Nov 17, 2013 6:34 am; edited 1 time in total (Reason for editing : not Motherland)


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k100lt 1989 abs
    

Guest

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And the jet engine was invented in England. The first jet airliner was English.
The French did not do too bad either. That symbol of Americanism, the statue of liberty was made in France.

    

TacKler

TacKler
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I thought Fokker was originally a Dutch design? 

Did zee Germans lose in both WW1 & WW2?  Hmmmmm... Interesting.  Maybe the K bike was their next attempt at world domination.


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Red 1991 K75S
    

MikeP

MikeP
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@TacKler wrote:I thought Fokker was originally a Dutch design? 
It/he was. Fokker tried flogging his designs to the British but when he failed to interest them, he went to the Germans.


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1992 K1
1993 K1100R (used to be an LT)
    

duck

duck
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About 3/4 of the time you can get the clutch switch out using needle nose pliers.


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Current stable:
86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
K75 Frankenbrick (Paralever, K11 front end, hybrid ABS, K1100RS fairing, radial tires)
86 K75C Turbo w/ paralever
94 K1100RS
93 K1100LT (x2)
91 K1
93 K75S (K11 front end)
91 K75S (K1 front end)
14 Yamaha WR250R
http://www.ClassicKBikes.com
    

88

88
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Elegant solution once again SCP  A 'spanner' to undo the handlebar clutch switch 112350


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A 'spanner' to undo the handlebar clutch switch Ir-log1188....May contain nuts!A 'spanner' to undo the handlebar clutch switch Ir-log11

"The world is a book and those who do not travel read only one page." - St. Augustine from 1600 years ago & still true!

Bike: K100LT 1988. 0172363. AKA the Bullion Brick! Mods: k1100 screen and stands.
K1: 1990. 6374189. Custom Stealth Black paint.
    

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