I just got an 05... - 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 04-19-2014, 08:53 PM Thread Starter
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I just got an 05...

I'm hoping this is a simple fix on my 2005. I accidentally dropped my bike and part of the clutch hand lever broke off. It rode fine afterwards and I even rode it to the parts place to buy a oem hand lever. I figured I could swap it out myself and after some trial and error I did just that. Now the bike won't start. The neutral light goes on but it does nothing at all when I try to start it. Any ideas?
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post #2 of 7 Old 04-19-2014, 08:57 PM
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There's a clutch safety switch incorporated into the mount. Be sure that the wires didn't come unplugged when you replaced the lever. I'm guessing that's what it is

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post #3 of 7 Old 04-19-2014, 09:10 PM Thread Starter
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Is it the 2 tiny Philips head screws near the bottom side of the lever. I think I did a crap job for my first lever switch.
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post #4 of 7 Old 04-19-2014, 10:57 PM
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Quote:
Originally Posted by Reed View Post
Is it the 2 tiny Philips head screws near the bottom side of the lever. I think I did a crap job for my first lever switch.
To be honest, I've never had my switch assembly apart on my KLR (gen 2, might be different anyway?). I was thinking of another bike I had that had a connector up by the clutch perch that slid onto the clutch safety switch. If the connector came partway off that was enough to keep it from starting. I'd check everything in the area you were working to ensure nothing came unplugged or got jarred. There are lots of tutorials on the net for bypassing the switch but I personally wouldn't recommend it for liability reasons.

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post #5 of 7 Old 04-19-2014, 10:59 PM
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Oh, and as far as a crap job, you learn by doing . Hoping you have a manual on hand, it's worth it's weight in gold!

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post #6 of 7 Old 04-19-2014, 11:33 PM
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Make sure that you use a good chassis grease to lubricate the lever pivot bolt. It makes quite a difference in ease of operation and wear if you keep them lubed, once a year,

When swapping a Gen2 clutch lever, watch out how you insert the lever as an acquaintence snapped the little plastic extension off the switch. It sticks out of the switch and the lever just fits in nicely to snap it off. Since he told me, I've been watchful and good thing!

HIH

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post #7 of 7 Old 04-19-2014, 11:51 PM Thread Starter
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Thanks everybody.
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