Fussy clutch safety switch with replacement lever

Started by Teek, June 01, 2008, 02:33:57 PM

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Teek

I got a set of replacement levers (in a "carbon fiber" paint scheme to match the Yoshi can) off eBay so we all know they are Chinese knockoffs. I let my hubby do the work after I made sure the pivot bolts were clean and everything lubed. He had to remove the clutch safety switch, was careful, did not break any of it, and now with the screws tight it won't work, with them out partway it will. I also noticed that the clutch lever released a little more on its own as I was backing the screws out. So after searching it and seeing someone else had the same problem, I realized that the toggle on the switch doesn't fit with the knockoff levers quite right, so when the screws are fully tightened it locks the toggle from moving.

So which do y'all think is better, shave the toggle end a bit or just put a dab of black silicone sealer on the screws to keep them from vibrating loose? It's just right right now, and I want to keep the safety aspects of the switch, as a couple other people are priviledged enough to ride my bike and their bikes are the same (so well I guess it doesn't matter, they pull the clutch in from habit!), but if I ever *gasp* sold it...

Also wanted to post in case someone else has this problem with new cheap levers, this is easier than changing the wiring to defeat the switch.
2001~ OEM Flyscreen & Chin spoiler, Fenderectomy, Sonic Springs, '05 Katana 600 Shock, Yoshimura RS-3 Carbon Fiber can, stainless midpipe, custom brake pedal, K&N Lunch box, Rejet, 14t sprocket, Diamond links, Iridium plugs, Metzeler Lasertecs, Hella horn, "CF" levers, Chuck's Fork brace. I'm broke!

pjm204

I just got rid of the clutch safety all together. I realize it is a safety feature but my old bikes don't have it and it kept on coming loose on this bike. I still pull in the clutch as good measure.
2001 GS- Lunchbox, jetted, fenderectomy, supertrapp exhaust/headers

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