Here's an easy guide to whats happened so far:
> 4 months ago dropped bike, bent clutch lever
>Bike runs fine the whole time, just cosmetic
>Get new OEM lever (1997 GS500E)
>Remove bolt/nut and pull out lever
>Youtube videos failed to tell me there is a clutch switch, so i accidentally snapped the POS plastic switch
>Realize how the switch works and move it to "clutch is in"
>Put together new lever and see if I actually need the switch
>Clutch lever moves back and forth, but doesn't do anything
>Bike starts in neutral, but lurches/dies when switched into gear
>Realize that I can shift freely between gears whether the bike is on/off/clutch pulled in/clutch pulled out
>After I switch the clutch switch a few times, the bike will no longer start in neutral like before.
Where do I even start here? I had a bike with a small cosmetic issue and I feel that I completely destroyed in one fell swoop. I'm pulling my hair out here on what to do.
NOTE: I may just solder together the wires and removed the clutch switch altogether. So my main question is, why are the gears shifting without the clutch lever in, and how can I fix the clutch lever/cable so that it works properly?
The switch is a completely separate system from the actual clutch operation. Breaking and then bypassing the switch cannot mess up how the clutch functions or how the bike shifts.
Are you sure you re-installed the clutch cable properly into the lever? How much free play is there in the clutch lever?
When in doubt, just do a full 3-point clutch adjustment.
(http://img.photobucket.com/albums/v443/jcp8832/GS500clutchadjustment_zps58ca4ce8.jpg)
The clutch switch is just an ignition cutout that kills the sparks when the bike is put in gear with the clutch not pulled in.
Designed for safety, so you can't put it in gear with the clutch lever out. Quote: "Bike starts in neutral, but lurches/dies when switched into gear".
Yes, just make up a little 'jumper' connector that joins those two wires that (used to) go to the lever.
It seems like we have a similar issue, though we arrived at the same place. After cleaning out inside my sprocket cover and reattaching my clutch won't seem to disengage and I can also freely change gears without pulling in the lever. Haven't had any luck resolving it. I'll be doing extensive work on it after the weekend. I'll let you know if I make any progress that may help. The 3 point adjustment didn't help me.