OEM clutch lever question regarding cutout switch

[user11235813]

Just bought a replacement clutch lever for GS500, it will do the job as it fits but it doesn't have the bit on the bottom that engages with the safety switch that won't let the bike start in gear with the clutch out. I'll use it as a spare when I get a replacement, but I was wondering what year would it have been that Suzuki began using the switch on the clutch lever,

[qcbaker]

The clutch safety switch is a separate part that screws into the lever housing, it isn't on the lever itself.

[mr72]

That's right but there is a "nub" or something on the OE clutch lever that engages the switch. An aftermarket lever may not have the correct cutout or nub or whatever it is (I can't remember).

[qcbaker]

That's right but there is a "nub" or something on the OE clutch lever that engages the switch. An aftermarket lever may not have the correct cutout or nub or whatever it is (I can't remember).

Ahh, I think I misread what the OP was asking about. Yeah, theres a small cutout on the bottom of the lever that the switch fits into once its screwed into the bottom of the lever housing.

As for OP's question of year-compatibility, as far as I know the GS500 has has the clutch safety switch since its inception in 1989. Here is a parts diagram for the handles/levers for the 1989 model:

Parts 15-17 on this diagram are the clutch safety switch

[mr72]

Right. And notice there's a little recess in the bottom of the lever that actually actuates this switch. Looks super unreliable to me anyway. Apparently it's somewhat common for folks to put aftermarket levers on without noting the lack of the recess and they break the switch. Switch is long gone on my bike from before I owned it so I'm not 100% sure.

Anyway, that switch is literally in series with the engine-start button. You can just short the terminals together and the bike will work fine without it. But you will have to be on alert enough to not try to start the bike in gear. My personal experience tells me you will only make that mistake once 

[qcbaker]

Right. And notice there's a little recess in the bottom of the lever that actually actuates this switch. Looks super unreliable to me anyway.

Never failed on me when I had it working on my bike, so I can't speak to the reliability. Only reason I posted the pic was to show that the part has existed on the bike since its inception.

Apparently it's somewhat common for folks to put aftermarket levers on without noting the lack of the recess and they break the switch.

I sort of did the opposite lol. My aftermarket levers had the recess, but I forgot to unscrew the switch when removing my old levers and damaged the nub when I pulled the clutch lever out by force . I basically rounded off one side of the nub, so the switch itself still "worked" but the lever no longer actuated it properly. I simply unscrewed the switch and filed the plastic nub down so it no longer protruded through the lever housing, moved the switch into the "engaged" position, and screwed it back in. It's worked fine ever since.

Anyway, that switch is literally in series with the engine-start button. You can just short the terminals together and the bike will work fine without it. But you will have to be on alert enough to not try to start the bike in gear. My personal experience tells me you will only make that mistake once 

I park my bike in neutral 99.9% of the time, so its never been a problem for me, but I'm sure I'll do it eventually lol.

[J_Walker]

who forgets to clutch in when starting their bikes anyway, unless you where trained by a pig, I doubt it's even a problem. don't think I've ever lurched a motorcycle on startup. I have missed neutral a few times at a stop light and let go of the clutch...