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1Back to top Go down   Clutch Switch Problem! Empty Clutch Switch Problem! Sat Oct 06, 2012 6:40 pm

Motorandy123

Motorandy123
active member
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Hi Guys,

I ordered up a used clutch switch as mine was bad. The new one had an intermittent but I
fixed that. It was tough getting to old one out and new one in but I managed that. Now
the switch doesn't work, it's always reading open unless I pull the handle out of the mount.
I tried adjusting the switch but it gets loose quickly and didn't adjust enough. I think maybe
the plastic bushing in my handle is worn. Do you think that would do it? Could I fill off some of
the handle to make it work? Here's a couple of pictures;

Clutch Switch Problem! DSCN1867

Clutch Switch Problem! DSCN1865


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MotoRandy123
1991 K75 "Special Edition"
    

2Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sat Oct 06, 2012 7:46 pm

Inge K.

Inge K.
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I`m in doubt that the worn pivot bushing would affect your clutch switch.

Easy enough to judge...look through the opening at front, when the lever is pulled.
It should be a couple of mm of air between the plunger and the lever itself.

If it is the pivot bushing that is the problem, I would rather tried fit a new bushing
(brass tube, or similar)...than removing material from the lever.

The pivot bushing you get as a single part, part #32 72 1 451 796.



Last edited by Inge K. on Sat Oct 06, 2012 8:07 pm; edited 1 time in total (Reason for editing : Adding info.)


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

3Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sat Oct 06, 2012 7:51 pm

chrish8846

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I think that the threads would have to be stripped for the switch not to hold adjustment, and the handle bushing is perished as the Brits say.

    

4Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sat Oct 06, 2012 7:56 pm

Inge K.

Inge K.
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It`s no adjustment on this switch, it have a fixed position.


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Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

5Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sat Oct 06, 2012 8:31 pm

charlie99

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have a look at the motobins site for the part ....

it seems to me that there should be a nylon or brass section in the pivot area of the handle ...

my thinking is that the cable will pull the handle closer to the switch mechanism ///but if the switch was intermittent could this not be contacting as well as a new one ....meaning that there might be too much travel before the actuall contacts make connection ?

just some thoughts


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

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%OClutch Switch Problem! Au-log10

'86 k100 rs.. #######..  "Fred " (f(rame) red ) ( Fredrick leichtundschnell ) - -
bits and pieces from many kind friends across the k100 world ...with many thanks ..
    

6Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 4:02 am

ReneZ

ReneZ
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Have a look at your bike ( Very Happy ) clutch switch, front and rear brake switches and the choke switch are all the same IIRC. Further the clutch handle is supposed to be kept pulled in the grip through the action of the spring in the clutch pin booth. If the handle is rattling I'd replace the nylon bush.


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Greetings from Florida! Having a 'new' K  :cyclops:    Surprised-o: 

Rene


BMW K100 - 1985 (0030029) Clutch Switch Problem! Rain
BMW K1200GT - 2003 (ZK01223)
    

7Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 9:41 am

Motorandy123

Motorandy123
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Well I found this picture;

Clutch Switch Problem! Handlebar

I see a bolt, wavy washer, and nut which I have on mine. I guess my question is when should it short
retracted or when pulled in. I cannot really see what's going on with the cable attached. I've been
setting it in place with the cable on and no bolt through it but moving it around does not change the
reading...


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MotoRandy123
1991 K75 "Special Edition"
    

8Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 9:54 am

Inge K.

Inge K.
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It should short when retracted.


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Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

9Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 10:00 am

RicK G

RicK G
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Often those clutch switches need some encouragement to work. Push the plunger and let it flick out quickly and if it then works soak it in some petrol (gas) then work it around you will be amazed just how much grunge comes out, then it might work again maybe. I have fixed a few but also thrown a few away, the spring inside loses its tension.


__________________________________________________
"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived."   Dalai Lama


Bikes 2004 K1200GT 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki
    

10Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 3:15 pm

Motorandy123

Motorandy123
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The old switch was toast. It never came back out and the inner part rotated. The
new one had intermittent wires and then was also intermittent itself. I cut the
wires down and since my new spray can of DeoxIt came in I gave it a shot of that.
It works fine just not triggered when the lever moves. I did find they sell the bushing
for $2 but I don't have an order right now. So I guess I'll try making my own and see
if that fixes it.

Thanks everyone for all your help! Just a couple more things and I should be up and running!


__________________________________________________
MotoRandy123
1991 K75 "Special Edition"
    

11Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 3:38 pm

sidecar paul

sidecar paul
Life time member
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Just remembered that, many years ago, I used to turn some of the metal body away so that the switch (rear brake in this case) sat deeper in the housing to get it to work. With the later switches I've not had this problem and they are much more reliable than the early switches although they look the same.

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!
    

12Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 4:23 pm

Motorandy123

Motorandy123
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Well I was looking for something to make a new bushing and I removed the cable to try it
and it worked! I hadn't put the shaft in when I tried it before so it probably was working
all along! So I can try to start it now once I get the fuel pump working. I assume it's not
working as I don't hear it when I turn the key on. It should make some noise right?


__________________________________________________
MotoRandy123
1991 K75 "Special Edition"
    

13Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 4:27 pm

Inge K.

Inge K.
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@Motorandy123 wrote: I assume it's not working as I don't hear it when I turn the key on. It should make some noise right?
It would be correct on Motronic equipped bike, on yours the fuel pump should start when you press the starter button.


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

14Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 4:43 pm

Motorandy123

Motorandy123
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Oh OK. I never had it running yet and thought it would pressurize first. I'll just get the
dash back together and give it a go then!


__________________________________________________
MotoRandy123
1991 K75 "Special Edition"
    

15Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Sun Oct 07, 2012 5:08 pm

Inge K.

Inge K.
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If the fuel system have been emptied, it could be a good idea to just touch the starter button a few times...to fill up the system.
The fuel pump would run a couple of seconds each time.


__________________________________________________
Inge K.
K100RS -86. (first owner), K1100LTSE -94.
    

16Back to top Go down   Clutch Switch Problem! Empty Re: Clutch Switch Problem! Mon Oct 08, 2012 12:31 pm

Motorandy123

Motorandy123
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Will do. That will be a good test to see it is working too!


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MotoRandy123
1991 K75 "Special Edition"
    

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