Clutch safety switch help - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 7 Old 03-21-2014, 08:29 PM Thread Starter
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Join Date: Oct 2011
Location: Louisville, KY
Posts: 67
Clutch safety switch help

Just bought a Magura hydrolic clutch for the 07 KLR. Looks great but....... It didn't come with either a safety switch or a work around. It didn't even mention it in the instructions. I called them and they sold me one for about $23. OK. The switch they sent has a 2-wire plug and the stock switch is a 3-wire setup. I called them back and asked how to wire it up and they said they don't have an answer. Not the response I had hoped for. The stock switch has a black/yellow wire that must go to the negative battery I'm not sure. Next a blue that I think may be positive and a teal color which must go somehow to the starter. My guess is that this is a 2 position switch so I'm lost. The new switch only has a black and a blue. Anyone have a clue as to how I should wire this thing.
Thanks
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post #2 of 7 Old 03-21-2014, 09:22 PM
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Join Date: Jan 2011
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Not trying to blow you off, Bigryamaha, but . . . I'm unfamiliar with the Magura clutch.

This may help:

http://www.wiringdiagrams21.com/wp-c...ng-diagram.gif

Some disable/override the clutch safety switch by shorting it, connecting the starter circuit relay to ground at all times, whether the clutch lever is pulled or not. You might consider that work-around, if you can live with the bike starting in any gear.
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post #3 of 7 Old 03-21-2014, 10:02 PM Thread Starter
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Join Date: Oct 2011
Location: Louisville, KY
Posts: 67
I have a switch

Since I have a switch I'd rather use it but just not sure how to wire it.
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post #4 of 7 Old 03-21-2014, 11:06 PM
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Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
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The center pin on the factory clutch lever housing is not used. The outermost 2 pins are connected together and complete the circuit when the lever is pulled in. Here is a link to Tom's bypass explanation with some pics. hope this helps you sort yours out.http://www.klrforum.com/showthread.php?t=13841 On page 2 Tom's HUGE fingers are seen holding the 3 wire plug with wires only in the outermost positions.
Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!

Last edited by justjeff; 03-21-2014 at 11:13 PM.
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post #5 of 7 Old 03-21-2014, 11:43 PM Thread Starter
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Join Date: Oct 2011
Location: Louisville, KY
Posts: 67
Great tip

Tha a for the solution. I'll first try to connect the two outer wires to the new switch. If that doesn't work I'll just short it
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post #6 of 7 Old 03-23-2014, 12:47 PM Thread Starter
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Join Date: Oct 2011
Location: Louisville, KY
Posts: 67
Up in smoke

Strangely it wasnt the outside wires but got the wire around to work. Noticed upon install that the clutch line ran pretty close to the head pipe when installing so I wire tied it to what I thought would hold it clear. Rolled it out in the driveway to warm it up and soon got a big plume of smoke. You guessed it. Vibration loosened it and got against the head pipe and burnt the line and the fluid instantly. Gotta order a new line, fluid, and fab a bracket to make sure it stays in a safe place. What a pain
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post #7 of 7 Old 03-23-2014, 09:50 PM
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Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
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Well! My harness only has 2 wires in the 3 wire plug. The center hole is not used. Sorry for the confusion!
Too bad about melting the new line! Would you care to mention where you bought the kit from and how much it was?

Regards....justjeff

It's not a Tractor....It's a LOCOMOTIVE!! Chugga Chugga
Woooo WOOOOO!!!!!
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