Clutch switch checking, cleaning and/or replacing.

Guides on all things big and small

Moderators: Steve-TC1, red_zx9r, yorkie, shamus13

Clutch switch checking, cleaning and/or replacing.

Postby yorkie » Fri May 01, 2009 7:02 pm

Clutch switch checking, cleaning and/or replacing, with pictures. 8) Pt No 27010-1094

Make sure bike is out of gear before you start.

This will help sort out, Bike won't start with clutch in, Engine only starts in neutral with clutch out, bike only starts with clutch held in, and other variations.

If the engine does not turn over with the shorting link fitted as shown it the pictures, then its not the clutch switch, but clean it anyway.

Tools 5mm allen driver or key
Large instrument screw driver or small screw driver
Scotch brite or similar, see last picture.

As with most of the write ups, it's worth reading through the replies for for more information or problems you may come across.


ImageImage


ImageImage


Image


ImageImage


ImageImage


Image


ImageImage

Coat the contacts in Vaseline after cleaning to help stop future corrosion.

ImageImage

Now put the bike back together.
Last edited by yorkie on Fri Apr 13, 2012 11:09 am, edited 6 times in total.
Just got yourself a ZX-9R, then do your bike, and yourself a favour, read this thread. viewtopic.php?f=21&t=28097

Please will forum members put their bike model letter, & 1 or 2 after their Profile Location. eg: Your Town & B1,2,3,4 C1,2 E1,2 F1,2
As all zx9's are all slightly different, and I get fed up having to ask which model & number, as year may not be accurate.
User avatar
yorkie
Ninjaneer
 
Posts: 11280
Joined: Mon Sep 25, 2006 5:46 pm
Location: Altofts Yorks. Blue 9C2 9F2 & 12B4

1999 Kawasaki ZX9R C2

Postby Del » Fri May 01, 2009 8:04 pm

:smt023
Tighten till it strips, then back out a half turn.

ZX9r - C1 - Almost ready for sale
GSX1400 - K2
ZRX1100 - Project
GSF1200 - New Hack
User avatar
Del
Carlos Fandango
 
Posts: 11821
Joined: Sat Oct 07, 2006 7:08 am
Location: WeegieLand (Glasgow)

1998 Kawasaki

Postby Steve-TC1 » Sat May 02, 2009 2:38 pm

Nice write up , thanks Yorkie =D> =D> :!:
For Paypal Donations Please Use steve1@zx-9r.net

Image
User avatar
Steve-TC1
Top Cat
 
Posts: 38052
Joined: Fri May 05, 2006 12:47 am
Location: Manchester

Postby shamus13 » Sat May 02, 2009 5:28 pm

=D> =D> =D>

Shamus
SHAMUS

Image
"If you can't express it in numbers it's not engineering, it's opinion."

BEX-MOTO
User avatar
shamus13
Moderator
 
Posts: 6409
Joined: Mon Sep 18, 2006 9:13 pm
Location: HULL

1996 Kawasaki

Postby coops86 » Sat May 02, 2009 7:01 pm

Even I could follow that :D =D> =D> =D> =D>
Kawasaki ZX9R E2 (The Missile)
Nissan Z350 0 - 1 ZX9R
Mitsubishi Evo 0 - 2 ZX9R
BMW M3 0 - 2 ZX9R
Subaru Impreza 0 - 1 ZX9R
User avatar
coops86
VIP
VIP
 
Posts: 6941
Joined: Mon May 12, 2008 4:57 pm
Location: East Yorkshire

2002 Kawasaki ZX9R E2

Postby Win9R » Sat May 02, 2009 10:18 pm

I don't need this because someone fixed mine last weekend! :D =D>
Paul

Does not play well with others!

RIP F Model
User avatar
Win9R
Ninja Guru
Ninja Guru
 
Posts: 1940
Joined: Mon Apr 17, 2006 10:14 pm
Location: Nottingham, ENGLAND

Postby chance » Sat May 02, 2009 11:12 pm

good write up =D> =D> =D>
2008 Triumph speedtriple
2004 ktm 525 supermoto
2004 ktm 450 exc supermoto/enduro
2003 kawaski zx12r b2h
2002 suzuki gsxr750 k2 trackbike
1991 yamaha tdr250
1991 yamaha tdr125 project shed
Image
User avatar
chance
Ninja Guru
Ninja Guru
 
Posts: 8987
Joined: Mon Oct 30, 2006 9:22 pm
Location: lincolnshire

2007 _Honda Fireblade

Postby Skunkwurcx » Sun May 03, 2009 12:09 am

yorkie wrote:If the engine does not turn over with the shorting link fitted as shown it the pictures, then its not the clutch switch, but clean it anyway.


Thanks for posting this Yorkie...I went ahead and did this but no joy.

Bike starts with short wire in both positions. Took switch apart. It wasn't the cleanest sight, but contact patches looked clean. Cleaned it up anyway. Side note - one of the mounting screws is sheared off, so either someone has had this off before or it was sheared off at assembly. The latter seems more likely as there was no evidence that the remaining screw had been turned, but who knows :smt102

So, cleaned and back together - bike won't start with lever pulled in and bike in gear. Will start with bike in neutral and slightest release of clutch lever(won't start with clutch lever pulled all the way in) and thru all the travel on the way to being fully released. Any ideas ? Tried wiggling harness but impossible to do that, hold in lever and press fire button all at the same time.
The Kaw Herd :
1977 Z1000
2002 ZX9R-F1
2002 ZRX1200R-A2
EX500(GPz500) - ARL #11, The ZX9's retarded cousin.

Image
User avatar
Skunkwurcx
Ninja Guru
Ninja Guru
 
Posts: 2828
Joined: Fri Nov 07, 2008 9:16 pm
Location: Nova Scotia, Canada's Tropical Paradise

2002 Kawasaki ZX9R F1

Postby yorkie » Sun May 03, 2009 1:34 pm

Still sounds like it could be the clutch switch. Unplug it, remount the clutch lever, put the shorting link in for clutch in, put it in gear and pull the clutch lever in, and see if it starts then. if it does then the clucht switch ain't working and its the spring under the 3 dimpled bit thats weak.
Just got yourself a ZX-9R, then do your bike, and yourself a favour, read this thread. viewtopic.php?f=21&t=28097

Please will forum members put their bike model letter, & 1 or 2 after their Profile Location. eg: Your Town & B1,2,3,4 C1,2 E1,2 F1,2
As all zx9's are all slightly different, and I get fed up having to ask which model & number, as year may not be accurate.
User avatar
yorkie
Ninjaneer
 
Posts: 11280
Joined: Mon Sep 25, 2006 5:46 pm
Location: Altofts Yorks. Blue 9C2 9F2 & 12B4

1999 Kawasaki ZX9R C2

Postby Skunkwurcx » Sun May 03, 2009 9:40 pm

yorkie wrote:If it does then the clutch switch ain't working and its the spring under the 3 dimpled bit that's weak.


If I say "what spring under dimpled bit" that will pretty much take care of that idea. I was real careful when I took the switch apart, and have gone and looked around the area where I did it and it ain't around....so unless it zinged into oblivion, there wasn't one in it which is why it won't work.

So seeing as though one of the switch mounting screws is sheared off in the lever perch, I guess I may as well get one of them. Kawi reports the same part #'s for at least 01's and 02's as being the same so.....

I'll mount the clutch lever with the by-pass though to be sure.

Thanks Yorkie
The Kaw Herd :
1977 Z1000
2002 ZX9R-F1
2002 ZRX1200R-A2
EX500(GPz500) - ARL #11, The ZX9's retarded cousin.

Image
User avatar
Skunkwurcx
Ninja Guru
Ninja Guru
 
Posts: 2828
Joined: Fri Nov 07, 2008 9:16 pm
Location: Nova Scotia, Canada's Tropical Paradise

2002 Kawasaki ZX9R F1

Postby yorkie » Mon May 04, 2009 10:24 am

The 3 dimpled bit I've not prized out, but on the one in the pictures, its sprung loaded from underneath.
Last edited by yorkie on Wed May 06, 2009 3:25 pm, edited 1 time in total.
Just got yourself a ZX-9R, then do your bike, and yourself a favour, read this thread. viewtopic.php?f=21&t=28097

Please will forum members put their bike model letter, & 1 or 2 after their Profile Location. eg: Your Town & B1,2,3,4 C1,2 E1,2 F1,2
As all zx9's are all slightly different, and I get fed up having to ask which model & number, as year may not be accurate.
User avatar
yorkie
Ninjaneer
 
Posts: 11280
Joined: Mon Sep 25, 2006 5:46 pm
Location: Altofts Yorks. Blue 9C2 9F2 & 12B4

1999 Kawasaki ZX9R C2

Success !!

Postby Skunkwurcx » Wed May 06, 2009 12:39 am

Went out and had a go at the switch again tonight....took it apart again and discovered that the spring is still under the dimpled bit...I had thought it was under the whole block that houses the dimpled plate #-o

Anyways, before I pulled the switch apart I did the short thing with clutch in and it turned over. With the switch apart again I inspected the springiness of the dimple plate, and while it doesn't seem to be too bad, it did seem to fetch up a bit. I compressed it a few times and put back together and it works !!!

I was going to go and order a new perch(switch screw sheared off) and switch, but now I can use the money I saved from buying those and buy the fork brace for the Z !!! So thanks again Yorkie !!!
The Kaw Herd :
1977 Z1000
2002 ZX9R-F1
2002 ZRX1200R-A2
EX500(GPz500) - ARL #11, The ZX9's retarded cousin.

Image
User avatar
Skunkwurcx
Ninja Guru
Ninja Guru
 
Posts: 2828
Joined: Fri Nov 07, 2008 9:16 pm
Location: Nova Scotia, Canada's Tropical Paradise

2002 Kawasaki ZX9R F1

Postby Win9R » Wed May 06, 2009 9:04 am

Nice one, Andrew. Glad to hear you fixed it in the end. =D>

Yorkie - Two down... :lol:
Paul

Does not play well with others!

RIP F Model
User avatar
Win9R
Ninja Guru
Ninja Guru
 
Posts: 1940
Joined: Mon Apr 17, 2006 10:14 pm
Location: Nottingham, ENGLAND

Postby Skunkwurcx » Wed May 06, 2009 12:20 pm

TWTZX9R wrote:Nice one, Andrew. Glad to hear you fixed it in the end. =D>

Yorkie - Two down... :lol:


Thanks Paul :D

I wasn't too worried about it as I always start my bikes in neutral. That said, it is good to have it working correctly for those, uh, little hiccups at traffic lights....that and if something is supposed to work, I want it to work. So we'll see how long this lasts for. New perches and switches aren't too bad pricewise.
The ones for our bikes are used on a great number of Kwaks from 6's to 12's so getting one off fleabay won't be painful if it should give up the ghost again.
The Kaw Herd :
1977 Z1000
2002 ZX9R-F1
2002 ZRX1200R-A2
EX500(GPz500) - ARL #11, The ZX9's retarded cousin.

Image
User avatar
Skunkwurcx
Ninja Guru
Ninja Guru
 
Posts: 2828
Joined: Fri Nov 07, 2008 9:16 pm
Location: Nova Scotia, Canada's Tropical Paradise

2002 Kawasaki ZX9R F1

Postby MR2Brett » Fri Apr 13, 2012 11:12 am

I had a problem with the clutch switch not operating correctly, so i took it apart and cleaned it as suggested, when i put it back on it worked for a few times then the same fault appeared. The fault was I could put the bike in gear with the engine running and the clutch pulled in but as soon as i let the clutch out the engine died. I then bought a switch from Cornwall Kawasaki and fitted it and guess what...........the same fault was there, i then traced (with the aid of a wiring diagram)the fault to be the earth on the horn, although the horn worked the earth connector was a bit corroded so i cleaned it up and crimped it a bit to give a tighter fit and the clutch then worked perfectly. So before you condemn your switch try cleaning the terminals up on the horn. ;)
Everyone has a photographic memory. Some just don't have film.

When the only tool you own is a hammer, every problem begins to look like a nail.
User avatar
MR2Brett
WSB Rider
WSB Rider
 
Posts: 329
Joined: Fri Oct 21, 2011 5:29 pm
Location: BORDON

2000 Kawasaki ZX9R E1

Next

Return to How To Guides

Who is online

Users browsing this forum: No registered users and 1 guest