Annoying Clutch contact preventing bike from starting

[tussey]

So I installed new handlebars today. Now the damn clutch contact isn't working. The clutch isn't moving the plastic contact piece far back enough to contact the two strips of metal and complete the circuit. I'm nearly ready to bypass it? Any suggestions on fixing it or should I just bypass it?

p.s. I'm talking about the little switch inside the clutch handle that moves a piece of metal back and forth depending on if the clutch handle is in or out. when pulled in it moves the piece of metal back and completes a circuit which will allow your GS to start. With an incomplete circuit nothing happens when you try to start the bike.

[Egaeus]

Is it connected correctly?  You didn't take it out and turn it around did you?

Worst thing is that you have to use your spare fuse to short the wires.  I rode like that for a month.

[runsilent]

I removed the wires to the clutch switch on my 97 GS500E, followed them into the headlight housing and just unplugged them there and plugged the two wires together in the housing.  Worked fine, my Hondas never had a clutch switch, the sidestand switch is all you need for safety.  Prevents riding off with stand down since engine dies when stand is put down with bike in gear and prevents starting bike in gear with sidestand down.

Was going to do same on the 02 GS500 but the wires to the clutch switch no longer had plug connectors, they just went directly into the harness in the headlight housing.  I didn't bother cutting and splicing, just left it alone.  Don't know what year they changed it.  The clutch switch completes the circuit between the 2 wires so you can just unplug them at the clutch switch and connect them together with a nail or something to try it out.

[tussey]

Is it connected correctly?  You didn't take it out and turn it around did you?

Worst thing is that you have to use your spare fuse to short the wires.  I rode like that for a month.

Yea it's installed correctly but the design is so poor that it can malfunction even when put together properly. What happens is the clutch handle hits the handlebar preventing you from pulling it in farther yet it's not enough to complete the circuit. From the looks of things the clip with the metal contact just sits in the hole and moves back and forth with the handle. It's not secured very well and leaves lots of room for error.

[Egaeus]

Is the clutch lever hitting the grip or the plastic switch assembly?  If it's the switch assy, then just rotate it a bit.

[tussey]

Is the clutch lever hitting the grip or the plastic switch assembly?  If it's the switch assy, then just rotate it a bit.

it's hitting the rubber grip on my bar. I can't pull it back any farther. 

[Egaeus]

Then something's wrong.  As far as that goes, a handlebar is a handlebar.  Did you put some really fat grips on it?  Are you absolutely sure that the switch is engaging the clutch lever correctly? 

[tussey]

Are you absolutely sure that the switch is engaging the clutch lever correctly? 

As far as I can tell. It sits very losely in its housing. I'm wondering if dabbing some grease in it wouldn't help it stay on the track better. Thoughts.

[tussey]

I finally said F it. I took the whole thing back apart today. I checked the operation of every component and everything is working correctly. Everything is installed correctly. It's not contacting by a fractional amount which is why jiggling it works 30% of the time. So I put everything back oh so carefully and it was a no go. I said F it and connected the wires in the headlamp bypassing the entire clutch contact circuit. Works like a charm everytime now.

NOTE TO SELF: DO NOT START ENGINE WITHOUT HOLDING CLUTCH IN 

[Egaeus]

Weird.  Yeah, like I said, I had a fuse shorting mine.  It came in handy if I wanted to start it one-handed.

[deathlucky]

could you make the swich abit taller or bend the cluch a wee bit to make it work

[tussey]

could you make the swich abit taller or bend the cluch a wee bit to make it work

Too much work to actually care about doing it. I just bypassed the circuit. Problem solved.