Will Not Start in Gear with Clutch Engaged - problem solved, thanks

[donaldcc]

  I'm traveling on bike for a week and everything good until we are way out in desert in southwest.  stopped for break and bike will not start in gear with kickstand up and clutch lever engaged.  Nothing, push starter and no response.  Starts up in neutral without problem.

   I know i have read about this problem and seem to remember not too complicated, but can't find it on search. Only 3 more days of travel so starting in neutral is OK.

  what am i forgetting about this hopefully simple  solution?  

[Mr.BubblesVRCCDS0008]

probably just need to clean your clutch switch located on upper end of lever. Easy fix.

[RTaz]

The bushing in your clutch lever is worn out, you can change it out or just get a new lever. Easy fix 

[donaldcc]

  Thanks!  will check it out when i return home in a few days. . . until then guess I'm starting in neutral.

[old2soon]

Had the same problem on my I/S. Cleaning that area got it wurking correctly again. I have since installed new Kury levers and am liking them a lot.  Got the Kurys off E-Bay for right at $33.00 delivered to my lacasa. RIDE SAFE.

[John Schmidt]

  Thanks!  will check it out when i return home in a few days. . . until then guess I'm starting in neutral.

For the record....that's always your safest bet anyway. Think about sitting on the bike, in the garage, and you start the bike in gear when suddenly your clutch m/c goes south on you. That's when you take out everything in front of you before the engine dies. I never start mine in gear unless I've killed it at a stoplight or similar, otherwise...always in neutral.

[Hoser]

Very good advice.  Hoser

[Gryphon Rider]

The bushing in your clutch lever is worn out, you can change it out or just get a new lever. Easy fix 

The bushing alone is not a replaceable part.  If the pivot hole in the lever is worn out, the whole lever needs replacing.  The OEM lever is inexpensive.

[R J]

NOT MEANING TO HIJACK THIS POST.
I can remember in the old days.
When we didn't have these safety switch(s).

We had just received a new batch of Harley's.
they were unloading them off the truck and lining them up nice and neat in a row.

The Captin came by & told us to get these bikes under lock and key.

He said I'll assist ya.
He jumped on one, feet down and he hit the starter,
she started and took the side out of his new Buick Patrol car.
This was like in 1954 or 55.

I'll remember that look on his face till my dying day.

I always start mine in neutral, even if I kill it at a stop light.

[valk2001]

I had the same problem and it was related to the kickstand switch and not the clutch lever switch.  Check the kickstand switch also.

[fantsybikr]

Had same problem, replaced the lever bushing for about 8 dollars

[Michvalk]

Did you check the plugin wires on the switch?

[JC]

Had same problem, cleaned switch, no problem.

Use a small piece of 1000 grit cloth if you have some and burnish the contacts in the switch.

[Ricky-D]

I would strongly suggest to never use an abrasive on the switch parts.

Reasons being numerous.

As a start,,,,,,,,,,, (1) there are many non-destructive ways to clean electrical contacts.

***

[RP#62]

I would strongly suggest to never use an abrasive on the switch parts.

Reasons being numerous.

As a start,,,,,,,,,,, (1) there are many non-destructive ways to clean electrical contacts.

***

Good general guidance but its really not an issue on a low volt low amp switch like this one.  I clean mine periodically with a sliver of 1000 grit paper.  As noted, you just need to polish the oxide off the points.  I recently found a small burnishing tool made for this purpose at a local electronics place.
-RP

[donaldcc]

  just home from long trip and work the next few days so will then get into it after that to check it out.  think it is clutch switch as kickstand switch seems to function fine.  wires to switch look OK on casual inspection.  will be taking a good look at clutch lever bushing that seem to be a likely cause and will make sure switch contacts are clean.

   will post what i find a few days down the road.

[JC]

I would strongly suggest to never use an abrasive on the switch parts.

Reasons being numerous.

As a start,,,,,,,,,,, (1) there are many non-destructive ways to clean electrical contacts.

***

Good general guidance but its really not an issue on a low volt low amp switch like this one.  I clean mine periodically with a sliver of 1000 grit paper.  As noted, you just need to polish the oxide off the points.  I recently found a small burnishing tool made for this purpose at a local electronics place.
-RP

My point exactly. Many older relays used to require an occasional contact cleaning, and the 'Burnishing Tool' is simply a tiny file made just for that purpose. They don't need sanding, just a light cleaning. 

[donaldcc]

The bushing in your clutch lever is worn out, you can change it out or just get a new lever. Easy fix  

The bushing alone is not a replaceable part.  If the pivot hole in the lever is worn out, the whole lever needs replacing.  The OEM lever is inexpensive.

Will not get to look at this until Mon or Tues.  You are talking about #2 that looks to be replaceable as a single part, $7.83 from Honda Direct Line?

probably just need to clean your clutch switch located on upper end of lever. Easy fix.

And you are just talking about cleaning the left side of #6 where the wiring attaches?

[JC]

probably just need to clean your clutch switch located on upper end of lever. Easy fix.

And you are just talking about cleaning the left side of #6 where the wiring attaches?

[/quote]

No, there is a small opening in the switch housing that you can get to when the switch is removed where you can access the actual contacts. You'll see it as soon as the switch is removed.

[Ricky-D]

Before removing the switch I would suggest to check it with a volt/ohm meter to determine whether or not it is working properly. Talking continuity here!

Kinda silly to do all that (r&r) without determining first, whether or not it is the problem.

***

[Gryphon Rider]

The bushing in your clutch lever is worn out, you can change it out or just get a new lever. Easy fix  

The bushing alone is not a replaceable part.  If the pivot hole in the lever is worn out, the whole lever needs replacing.  The OEM lever is inexpensive.

Will not get to look at this until Mon or Tues.  You are talking about #2 that looks to be replaceable as a single part, $7.83 from Honda Direct Line?

No, the #2 bushing has a hole in it to receive the end of #1.  #2 pushes on #1, which in turn actuates the clutch master cylinder.  #2 locates in the bottom right hole in the photo below.  The bushing that wears out to cause clutch switch problems is permanently pressed into the lever, and is brass-coloured in the photo.

[donaldcc]

  Thanks JC, Ricky-D and Gryphon Rider. Will check contacts with meter first to make sure I have power, clean them if I do and check bushing in lever.
 

[donaldcc]

  So after long 12 hour day at work i went out in garage to look at clutch lever assembly after getting off and reading the suggestions.  the brass colored bushing seemed fine and the clutch lever was pressing down OK on the pin on the switch, so didn't seem like that was the problem.

  I took off switch, sprayed some cleaner on it and tried to just clean the contacts off with some cotton strips pushed down along the surface.  Problem solved, started right up with bike in gear, kickstand up and clutch lever compressed.

  thanks for the advice guys, simple fix with the good advice.  

[RP#62]

Glad to hear it was something easy.  Mine did that when the bike was a year old and then again about two years later so I've made the cleaning of the switch an annual maintenance event.
-RP

[Allan]

I have the same problem, but cleaning didn't help.
I tried to by-pas the switch (connecting the to plug-In cables) but that didn't help either.

Any ideas?