Gen 2 Safety Switch Bypass - Page 4 - 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 #31 of 37 Old 04-10-2019, 11:31 PM
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Hello Tom I have a 2018 KLR I’m trying to install a new clutch perch/lever that does not a have a place for the clutch saftey switch. How should I go about installing the pro taper clutch perch/lever? Is this possible or do I need to run a OEM perch. If I by bypass it and remove it like your photos say could I just zip tie it to the frame? I’m not a very knowledgeable mechanic, but I know a few things. Just need a little guidance.
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post #32 of 37 Old 04-10-2019, 11:58 PM Thread Starter
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Install the Protaper to the bar. Do the bypass of the clutch safety switch and zip-tie the connector to the bar.

The switch is a part of the OEM lever, You needn't do anything with it once the bypass is done. Put in on the 'dead parts pile'.

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post #33 of 37 Old 04-11-2019, 12:21 AM Thread Starter
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I should note that the clutch switch connector is a three-pin locking type MTW .110 Connector and the kickstand switch connector is a two-pin Sumitomo MT 090 (with no bottom rib) connector. Thes are both available from CycleTerminal.

With these mating connectors, one can make a bypass that is every bit as reversible as the above, but which is more robust. It requires some effort and the ability to crimp open-barrel terminals.

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #34 of 37 Old 04-11-2019, 12:44 AM
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Thanks Tom I really appreciate the quick reply. I plan on doing this tomorrow. Do both bypasses have to be done, or can I just do the clutch safety bypass? Would you recommend just keeping the OEM clutch perch if I ever needed to adjust the bike back to normal? Will this cause any other unforeseen issues with the bike? (other than starting while in gear) It looks like a very easy project.

I’m new to the KLR world but I’m learning.

Regards, Jared Whitehead
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post #35 of 37 Old 04-11-2019, 01:35 AM Thread Starter
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Jared,

You can do just the clutch switch bypass.

Never throw anything away. That is, unless it is completely broken. It's always good to be able to put stuff back to stock. I'm not quite sure what the situation is with yours; you said 'stripped' but I'm not sure if that is in the sense of 'took it off the bike' or 'its threads are stripped so it is broken'.

Tom [email protected]

“Neither of the two people in the room paid any attention to the way I came in, although only one of them was dead.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #36 of 37 Old 04-11-2019, 01:47 AM
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It’s just the perch it’s self has stripped bolts, and won’t stay tight on the handlebar. I’ve already purchased the pro taper perch and clutch lever assembly, and at the time I didn’t realize the OEM perch had that safety switch connecter. So I was stuck today in the garage, and I didn’t want to mess with it because I didn’t know what I was doing.
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post #37 of 37 Old 07-12-2019, 02:09 PM
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Now you tell me! After I gnawed off my leg. By the way, it tasted like chicken. Wink. Thanks for the great advice like always.
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