Is it the Chicken or the Egg?

[Valkpilot]

Symptom: Bike won't start in gear with the clutch lever pulled in with either the kickstand up or down.

Diagnosis: Clutch switch is not being activated.

• Clutch switch works, i.e., makes contact when it closes
• It's not a worn push rod bushing; it's new.

Root cause question: Is the clutch switch push button worn, or is the clutch lever worn?  The clutch lever has a small divot where the push button makes contact, but I can't remember if it is supposed to be there or not.

There's a work-around in place.  I made a shim out of a piece of Diet Coke can and stuck it between the clutch lever and the switch push button, so everything works as it should for the moment.

[junior]

and you tested this switch? i.e. multi meter it can still click and not make contact

[Valkpilot]

and you tested this switch? i.e. multi meter it can still click and not make contact

Yes.  And, as I said, with a shim in place between the clutch lever and the switch push button, everything works as it should.

[John U.]

The bushing may be worn. This is from Jeff K's generic parts list:

The Honda part Number 2285-MBO-006 is $10
The Suzuki part number 59892-08A00 is $3 and exactly the same part.

[Valkpilot]

The bushing may be worn. This is from Jeff K's generic parts list:

The Honda part Number 2285-MBO-006 is $10
The Suzuki part number 59892-08A00 is $3 and exactly the same part.

It's new, as stated above.

[Ricky-D]

Leave the shim!

***

[Valkpilot]

Leave the shim!

***

That's certainly the direction I'm leaning!

[GJS]

Sounds like you nailed it.
I've got the exact same symptoms @ 60k miles.
Showed up just as my gal and I headed for Utah back in May, the problem disappeared after the first week. I had been thinking it through and had come to the same conclusion you have.

Good to know what worked for you.

Cheers,

Glenn

[Valkpilot]

Sounds like you nailed it.
I've got the exact same symptoms @ 60k miles.
Showed up just as my gal and I headed for Utah back in May, the problem disappeared after the first week. I had been thinking it through and had come to the same conclusion you have.

Good to know what worked for you.

Cheers,

Glenn

Interesting.  I turned 60k miles right about the time it started giving me problems.

[Robert]

Couldn't resist went outside and looked at mine. Kinda sorry I did found some dirt and spots starting to form on the chrome. But my switch the little arm that comes out is about 3/16 when its all the way out. When it makes contact and allows for starting the bike its out about 1/16 or a little more. Age,water the brake lever arm on the inside wear or the little plastic arm that comes out is not that strong. The screw that anchors it on looks like it may have a little adjustment available but it wont take much that's for sure.

[Valkpilot]

Couldn't resist went outside and looked at mine. Kinda sorry I did found some dirt and spots starting to form on the chrome. But my switch the little arm that comes out is about 3/16 when its all the way out. When it makes contact and allows for starting the bike its out about 1/16 or a little more. Age,water the brake lever arm on the inside wear or the little plastic arm that comes out is not that strong. The screw that anchors it on looks like it may have a little adjustment available but it wont take much that's for sure.

Thanks for taking the time to look at your set up and provide me with some details.

[Kingbee]

I had the same problem.  I drilled out the screw hole just a bit over stock size, and allowed me to move the switch just enough to make things work again.

[Valkpilot]

I had the same problem.  I drilled out the screw hole just a bit over stock size, and allowed me to move the switch just enough to make things work again.

That's a pretty good work around.

I'm still interested in knowing root cause, i.e., is it wear on the clutch lever or wear on the switch push button?

[Gryphon Rider]

With my bike the cause of the same problem was wear in the bolt hole in the clutch lever.  My old lever could wiggle when moved up and down.  The new lever doesn't wiggle, and the clutch switch works properly again.

[Cattman]

Just changed out my clutch lever with same symptoms. Hole where  the bolt goes thru the lever had worn to a  oval shape and let the lever move away from the switch enough to not engage. New lever and everything works fine.

[Valkpilot]

With my bike the cause of the same problem was wear in the bolt hole in the clutch lever.  My old lever could wiggle when moved up and down.  The new lever doesn't wiggle, and the clutch switch works properly again.

Just changed out my clutch lever with same symptoms. Hole where  the bolt goes thru the lever had worn to a  oval shape and let the lever move away from the switch enough to not engage. New lever and everything works fine.

I'll have to check those symptoms.  I know the hole doesn't look oval, but I haven't put a caliper on it to check.  Clearly it wouldn't take much, as a few thousandths of an inch thick aluminum shim fixed things up.   

Hmmmm.  If it's loose, maybe if I shimmed the bolt hole...

[Jeff K]

When you say you replaced the bushing are you talking about the bushing on the lever pivot, or the push rod bushing? They can both cause this problem.

[Joe Hummer]

With my bike the cause of the same problem was wear in the bolt hole in the clutch lever.  My old lever could wiggle when moved up and down.  The new lever doesn't wiggle, and the clutch switch works properly again.

Just changed out my clutch lever with same symptoms. Hole where  the bolt goes thru the lever had worn to a  oval shape and let the lever move away from the switch enough to not engage. New lever and everything works fine.

I'll have to check those symptoms.  I know the hole doesn't look oval, but I haven't put a caliper on it to check.  Clearly it wouldn't take much, as a few thousandths of an inch thick aluminum shim fixed things up.   

Hmmmm.  If it's loose, maybe if I shimmed the bolt hole...

Hey VP,

I have a set of stock levers at home.  If you are interested in replacing the clutch side, let me know.  Send me a PM. 

Joe

[Valkpilot]

When you say you replaced the bushing are you talking about the bushing on the lever pivot, or the push rod bushing? They can both cause this problem.

As stated in my first post, the push rod bushing is new.  

I've only ever heard about wear in the push rod bushing. I wasn't aware you could replace the pivot bolt bushing, as it is not shown as a separate item on the parts fische.  I guess you have to replace the entire clutch lever.  Thanks for that info!

[Jeff K]

When you say you replaced the bushing are you talking about the bushing on the lever pivot, or the push rod bushing? They can both cause this problem.

As stated in my first post, the push rod bushing is new.  

I've only ever heard about wear in the push rod bushing. I wasn't aware you could replace the pivot bolt bushing, as it is not shown as a separate item on the parts fische.  I guess you have to replace the entire clutch lever.  Thanks for that info!

I did some supercharger work on a guys Valk and everything worked fine. The day he came to pick it up it wouldn't start. Luckily I had a spare used clutch lever and swapped it out and sent him on his way.

[Valkpilot]

It's the chicken.  Or the egg.  Whichever, JoeValkIS sold me a like-new clutch lever and it fixed the problem. 

The new lever not only does not have the divot in the facing plane that meets the switch, but it also doesn't wiggle up and down as much indicating that part of my problem was in fact a worn bushing in the bolt hole.

[Jeff K]

It's the chicken.  Or the egg.  Whichever, JoeValkIS sold me a like-new clutch lever and it fixed the problem. 

The new lever not only does not have the divot in the facing plane that meets the switch, but it also doesn't wiggle up and down as much indicating that part of my problem was in fact a worn bushing in the bolt hole.

[Master Blaster]

Usually if you add lube pivot bushing to your annual to do list you wont have this problem.  Also if you have replaced the stock levers with nice shiny chromies and happened to save the old levers, you can drive out the bushings, and swap them out, and keep the shine.  Every spring I used to make an its time to lube the pivot levers post after it happened to me once.  Been  Kinda tied up the last couple of years, and got out of the habit.