Gen 2 Safety Switch Bypass - Page 2 - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #11 of 37 Old 05-15-2013, 04:49 PM
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Tom...I have a question about the 2008 clutch bypass. I have already done the bypass as I would have on any generation KLR, it worked well. But now I need to return it to where it was for a safety inspection. The problem being is, I don't have all the original plugs and wiring left as it was my second bike at the time so I never thought much about reversing the proceedure.
I have reversed the sidestand switch easily enough, but when I am looking at the clutch wiring under the lever I am slightly confused at the moment. I have a plug or the male part of the plug that goes into the female under the clutch lever. The problem it has 3 wires coming from it???? I have looked carefully at the remaining wiring on the bike and for the life of me can't decide if this is actually the plug that works in this location. It fits so it can be made to work by rewiring it. The problem is, I can see where I joined the typical wires together that I would do on any model of KLR, but because I removed the entire switch I have had to find another which I have.......I can't remember if the 08 and up have 3 wires coming from this switch or just two? If it's just 2 I am good and can easily figure it out. But if 3 then I am scratching my head wondering where the 3rd wire is supposed to be going.
Can you shine some light onto this for me?
Thanks.....

Willys
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post #12 of 37 Old 05-15-2013, 05:28 PM Thread Starter
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willys -

It's a two-conductor plug with a green/white wire and a blue wire.

Here's the best picture I could take; it's really sunny and the camera throws a shadow over the plug.



The center hole in the connector is empty.


The switch has three connectors, but the Gen 2 Sheet 1 here shows that the Starter Lockout Switch only has two active connectors.



T

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Last edited by Tom Schmitz; 05-16-2013 at 09:09 AM.
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post #13 of 37 Old 05-15-2013, 06:15 PM
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Thanks Tom, I knew if I didn't ask it would be the opposite of what it was supposed to be. Cheers......oh...your hands are looking kind of dirty....may I recommend the well known and reliable green elixer of products to clean them up....lol

Willys
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post #14 of 37 Old 05-15-2013, 08:38 PM
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Originally Posted by willys View Post
Thanks Tom, I knew if I didn't ask it would be the opposite of what it was supposed to be. Cheers......oh...your hands are looking kind of dirty....may I recommend the well known and reliable green elixer of products to clean them up....lol
What the heck Willys!? Now you're trying to promote Scope mouthwash as HANDCLEANER??
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post #15 of 37 Old 05-16-2013, 07:44 AM
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nice, thanks for bumping this thread.

this definitely looks like the most reversible back to stock fix i've found online. i'd hate to cut into the factory harness fresh out of the dealership. i'm guessing if you use the mini fuse for the clutch switch, the connector won't fit back together? i know even with the jumper it won't fully fit together but would look better and maybe offer some protection from the elements.

i foresee this mod in my very near future, awesome info guys
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post #16 of 37 Old 03-01-2014, 12:03 AM
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Hi, I have a '09 that was modified before I bought it. One issue that I am having with the bike is that I can not start it in gear with the clutch lever pulled in, on the side stand or up. I have checked the clutch switch to see if there is a jumper in there and there is not one. Does any one have any ideas how to fix this? It is a real pain trying to find N when you are also trying to hold the bike up on the side of a hill or at an intersection after I have killed it.
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post #17 of 37 Old 03-01-2014, 03:18 AM
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The starter circuit relay receives a ground to start the engine, either from the neutral switch, or from the clutch safety switch (with the clutch lever pulled).

Sounds like you're denied the latter; i.e., your clutch safety switch is inoperative. You can work around this problem by defeating the switch, with a wire segment or mini-fuse, as shown on the website threads, or fix/replace your clutch safety switch.

Irrelevant anecdote follows: I recently had the OPPOSITE problem; I could start the engine with the clutch lever fully pulled, but NOT with the transmission in neutral. Incidentally, no green neutral light, either. Cause? Using an electric impact wrench to torque the countershaft sprocket nut, the severe vibrations yanked the neutral switch wire connector from the neutral switch. Thus, the only ground possible for the starter circuit relay had to come from the clutch safety switch, until the neutral switch wire was re-connected to the switch terminal.
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post #18 of 37 Old 03-01-2014, 07:47 PM
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I put a jumper in and that took care of the starting issue. Thanks for your time and help with this.
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post #19 of 37 Old 03-02-2014, 03:29 AM
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I did both of those mods on my 2004 KLR a bit more difficult than the gen2. I found it a must after I broke a clutch cable, I can now put her in 1st gear and crank up on the starter to get going if need be, not tried the theory yet but this was not an option before.
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post #20 of 37 Old 08-23-2014, 09:48 PM
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I bypassed the clutch switch on my '09 three years ago and haven't regretted it (after my 1st symptom was not starting except in neutral when I was 24 miles off the rural highway and about 40 miles from any town). When I got back to town I used a paper clip bent into a squared "U" and that fit in very nicely (much like the 18 gage wire in Tom's first picture). Then put the plug back in place and taped it up with some quality electrical tape. I bought a new switch that I figure I'd install if I come to sell it someday. It's been bumped about and it sleeps in the car port where it gets some horizontal rain on occasion and I wash it a few times a year and everything has stayed put. I figure when the side stand switch craps out I can fix it pretty quickly by shorting the wires and then decide what to do with it long term.

Great forum you guys have here. Lot's of good info!

Thanks!
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