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PostPosted: Fri May 01, 2009 7:02 pm 
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Ninjaneer
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Location: Altofts Yorks. Blue 9C2 9F2 & 12B4
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.


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

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Now put the bike back together.

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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.


Last edited by yorkie on Fri Apr 13, 2012 11:09 am, edited 6 times in total.

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PostPosted: Fri May 01, 2009 8:04 pm 
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Carlos Fandango
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:smt023

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PostPosted: Sat May 02, 2009 2:38 pm 
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Nice write up , thanks Yorkie =D> =D> :!:

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PostPosted: Sat May 02, 2009 5:28 pm 
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=D> =D> =D>

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PostPosted: Sat May 02, 2009 7:01 pm 
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Even I could follow that :D =D> =D> =D> =D>

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PostPosted: Sat May 02, 2009 10:18 pm 
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Ninja Guru
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I don't need this because someone fixed mine last weekend! :D =D>

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PostPosted: Sat May 02, 2009 11:12 pm 
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good write up =D> =D> =D>

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PostPosted: Sun May 03, 2009 12:09 am 
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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.

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PostPosted: Sun May 03, 2009 1:34 pm 
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Ninjaneer
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Location: Altofts Yorks. Blue 9C2 9F2 & 12B4
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.

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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.


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PostPosted: Sun May 03, 2009 9:40 pm 
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Ninja Guru
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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

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

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 Post subject:
PostPosted: Mon May 04, 2009 10:24 am 
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Ninjaneer
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Location: Altofts Yorks. Blue 9C2 9F2 & 12B4
The 3 dimpled bit I've not prized out, but on the one in the pictures, its sprung loaded from underneath.

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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.


Last edited by yorkie on Wed May 06, 2009 3:25 pm, edited 1 time in total.

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 Post subject: Success !!
PostPosted: Wed May 06, 2009 12:39 am 
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Ninja Guru
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Location: Nova Scotia, Canada's Tropical Paradise
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.

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PostPosted: Wed May 06, 2009 9:04 am 
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Nice one, Andrew. Glad to hear you fixed it in the end. =D>

Yorkie - Two down... :lol:

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PostPosted: Wed May 06, 2009 12:20 pm 
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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.

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PostPosted: Fri Apr 13, 2012 11:12 am 
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WSB Rider
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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. ;)

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