Ignition Switch

[vrider]

Just replaced my ignition switch and now I have to start the bike in neutral.  There must be a clutch switch I missed. Can anyone help? Thanks

[Gryphon Rider]

There is a switch on the clutch lever. If it is malfunctioning you will have the problem you described. A related thing is the hole in the clutch lever that the bolt goes through can wear into an oval shape. This prevents the lever from depressing the switch. If the end of the clutch lever can wiggle up and down more than 1/8 inch or so, this is likely the problem. Replace the lever with a new one.

[Michelin Man]

Just unplug the switch on your clutch lever, cross it over, and see if it starts. If it does, see what's the problem. It could be a bad switch, or a worn bushing.

Curt

[HayHauler]

Try this from the JeffK's generic parts page in ShopTalk.  It's a Suzuki bushing that is exactly the same part as the Honda one, but $7 cheaper.  ($3).

59892-08A00

I ordered about 5 and gave a few away to friends that needed them.

Hay 
Jimmyt

[Gryphon Rider]

Good grief!  Not again about the bushing!  There are two bushings.  One is permanently pressed/cast into the lever and forms the hole that wears out into an oval shape preventing the switch from working.  You CANNOT buy that one separately but must buy the whole lever.  The other bushing (that HayHauler mentions) has absolutely nothing to do with the switch.  Its job is to push on the push rod which pushes in the piston of the master cylinder.

[Ricky-D]

When question about maintenance arise, it seems the simple stuff is often ignored.

Like for instance:

Oil the levers and foot brake along with the kickstand.

***

[art]

I'm having the same problem of not starting while in gear,what a pain trying to find neutral without the engine running. I'm going to pull the levers off and check the bushing. Having my own lathe I will make my own bushing. Keeps me busy during the rain.

[Tailgate Tommy]

Copied from an old post:
The Honda part Number 2285-MBO-006 is $10
The Suzuki part number 59892-08A00 is $3 and exactly the same part.

Today's prices may be more

[Denny47]

I must agree with Gryphon Rider. I think the bushing is sold as part of the lever. But, if a person were to take his pivot bolt and lever with him to a hardware store I believe it's possible that you might find a brass bushing close enough in size and press it into the lever.

[quexpress]

Another solution is to install a hydraulic brake/clutch switch such as this one:



http://www.ebay.com/itm/Motorcycle-Hydraulic-Brake-Pressure-Light-Switch-10x1mm-Honda-Suzuki-Kawasaki-/111209337147

I have installed a few of these on a 1985 Suzuki .... and have never looked back.  

If my Valk ever gets a clutch/brake switch problem, it will also inherit hydraulic switches.

[John Schmidt]

Another solution is to install a hydraulic brake/clutch switch such as this one:



http://www.ebay.com/itm/Motorcycle-Hydraulic-Brake-Pressure-Light-Switch-10x1mm-Honda-Suzuki-Kawasaki-/111209337147

I have installed a few of these on a 1985 Suzuki .... and have never looked back.  

If my Valk ever gets a clutch/brake swith problem, it will also inherit hydraulic switches.

Hey Normand, our two brains are in sync on this one(kinda scary). That's exactly what I did on a couple bikes that I coverted to Harley controls. You lose the clutch switch when doing the conversion, so I took a ride over to J&P Cycles store at Destination Daytona and picked up a couple of those hydraulic switches. I installed them down low and in line with the clutch tubing, just used the wiring for the clutch switch. Works great.  

Just noticed, you have a lispth when it comes to "swithes"....just had to yank your chain a bit buddy. 

[quexpress]

Yup! We are often on the same page John! 

Hey! Thanks for pointing out the typo bud!