Not Again?!?! Clutch switch failure! - Kawasaki KLR 650 Forum
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post #1 of 10 Old 10-06-2007, 11:22 AM Thread Starter
Join Date: Sep 2006
Posts: 135
Not Again?!?! Clutch switch failure!

When I bought my '08 KLR it came with a busted clutch lockout switch, which I had fixed under warranty. Well, now it's done it again. I didn't drop the bike, I hadn't been off-roading it and I hadn't recently dunked it in water. I simply shut it off and when I tried to start it again it had failed!

So what should I do? Have it fixed again or bypass the sucker?
My concern with bypassing it at this point is that there might be something causing the switch to fail that I might want to have fixed before it causes something worse to happen.

The down side to having the dealer (a bunch of jerks, in my case) fix it is that I have to take two (2) buses and walk a mile (round trip) to get it done.

Timbo is offline  
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post #2 of 10 Old 10-06-2007, 12:47 PM
5th Gear
Join Date: Sep 2006
Posts: 4,700
I'd have it fixed, but is there any chance of having a different dealer do it? I have a jerk dealer less than 1/2 mile from where I work, and I instead take it to a great dealer 35 miles from me..

I dunno, but while it's under warranty, I'd have everything addressed as many times as needed. After the warranty runs out, I'd bypass it..
Paper is offline  
post #3 of 10 Old 10-06-2007, 05:56 PM Thread Starter
Join Date: Sep 2006
Posts: 135
Yup, that's my plan... I used to think I could take my bike to any dealer I wanted, so long as it was warranty work I was having done (NOT).

The last time I tried this I was told that if they found out the problem was caused by one of the assembly techs where I bought it, they not only wouldn't cover it under my warrany, but they'd make me pay for the repairs and leave it up to me to try and collect my money from the selling dealership.

So much for using any dealer you like.

The service Mngr. said he would order the switch for me and see if I could simply drop by and have it installed while I waited.
Unfortunately he said this last time and it didn't happen. I still had to drop my bike off, take two buses home, then return two days later via the same two buses.

Timbo is offline  
post #4 of 10 Old 10-11-2007, 07:40 AM
Join Date: Jul 2007
Posts: 58
Tim, the switch probably isn't even bad, just misadjusted. Try adjusting it by loosening the mounting screws and moving it around until it behaves correctly. That worked on my 2003, although it seems to come out of adjustment again in a short while. I ended up just bypassing it.
michaeln is offline  
post #5 of 10 Old 10-11-2007, 10:17 AM Thread Starter
Join Date: Sep 2006
Posts: 135
Originally Posted by michaeln View Post
I ended up just bypassing it.
Thanks, Michael, I plan to do that just as soon as it's no longer under warranty. Someone on another board (I can't remember which one) said something about the brush guards pressing on the switch, or something like that, and causing it to fail.
I had just R&R'd the guards when it stopped working this time. hmmmmm

The good news is, the service manager told me that I could just drop by and have a new one installed while I wait (yeah right). I just have to make sure he's there when I show up so the jerks at the counter don't tell me differently.

Timbo is offline  
post #6 of 10 Old 10-12-2007, 06:58 AM
1st Gear
Join Date: Jul 2007
Location: central iowa
Posts: 61
safty switch

maybe im just lucky but havent had a bit of trouble with my 08 and have got over 5000 on it now. also havent tried to abuse it to much yet been commuting on it mostly, although i do live in the middle of nowhere its seen alot of gravel.
kw08klr is offline  
post #7 of 10 Old 10-12-2007, 10:04 AM Thread Starter
Join Date: Sep 2006
Posts: 135
Well that's just strange. I loosened the lower, left brush guard nut and the damn thing's working agian!
I guess the nut was putting pressure on the switch housing.

Pretty lame design.

Timbo is offline  
post #8 of 10 Old 10-12-2007, 12:59 PM
Join Date: Jul 2007
Posts: 58
That's what I was saying... adjust it, the switch isn't even bad. No need to put up with the dealer for something like that.
michaeln is offline  
post #9 of 10 Old 12-30-2007, 10:50 AM
Join Date: Oct 2007
Posts: 94
Next time a dealer tells you, you have to collect it from the selling dealer on a warranty item, ask for the address and phone number of the Kawasaki or Rolls Royce for that matter liasion in that area. It is not up to you to ferret out low life dealers but the manufacturer, that is the liasion's job. Usually attitudes change rapidly. As for your home dealer, go in and tell him he needs help, to repair your bike, and you'd like to know the liasion's name address and phone number so you can get him that help, you won't be liked there, but you will get your bike fixed and it will be on record as a warranty problem if you have the bike for 300,000 miles and Kawasaki will be reponsible for it, next is called better business bureau, enough complaints and stuff like this will cease, all it takes is customer participation.
erbie is offline  
post #10 of 10 Old 02-26-2020, 06:58 PM
Join Date: Feb 2020
Posts: 1
I added a jam nut so that the bark buster wasn't touching the switch.
Wirenut is offline  
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