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Dies going into gear

R

Rusty2000

Who dares wins!
Joined
Jan 12, 2019
Messages
24
Location
Portugal
Hi All,

2009 model, new problem not happened before. Bike starts fine but does going into gear. Won't start in gear either with no clicking from relays, just a dead starter. Is this a neutral sensor issue or a clutch cut-out sensor issue? Or is it entirely something else?
 
Having a lot of trouble with my sidestand switch at the moment, it operates sufficiently to put the dash light out but it is still in circuit somehow and makes the engine cut out when switching from Hi to Lo beam!
The only way to stop this happening (until I remove the switch this weekend) is to get underneath and pull the plunger out with my fingers.
As I say, the dash light goes out but the switch still makes the engine cut out.
 
Not easily, I looked at removing the switch a couple of weekends ago but was shocked at just how inaccessible it is.

It is held in place by two screws but although it is possible to remove these I am worried that re-fitting the switch is going to be a problem due to the lack of room (caused by the sump) to get the screws started (they are hex head and undo ok using a ball end driver but getting them aligned to start the thread could be tricky). I also tried to undo the connector but that is tight behind the starter motor and there was no way I could undo it without removing the starter.
Having proved that everything is ok as long as the plunger is fully extended it is my intention this weekend to remove the switch and hope that provides sufficient slack to undo the connector. If everything works ok with the switch out of circuit then I will leave it like that until I get a new switch but if is senses the switch is disconnected then I will reconnect and tie the switch up out of the way.
The trouble at the moment is that with the plunger having to be released manually I can't use the sidestand and as a rule I like to put that down when stepping off the bike (for stability) before then putting it on the mainstand.
 
The sidestand switch is a single pole single throw version (i.e. off or on only), so if it observed changing in the dash, then the switch itself is not the problem.

Don't understand how the Hi-Lo beam switch is affecting things. Has a previous owner been jerking around with the wiring perhaps?
 
No, owned from new and completely standard.

Can confirm that it certainly is the problem but as you say, can't understand how however I am confident that a new switch will cure it.
Flick up sidestand and the dash light goes out, put it into gear and all is ok but whenever the Hi / Low switch is moved to Lo then the sidestand warning light illuminates and the engine cuts out. Get off, pull the plunger out a little more (it is sticky despite being cleaned so suspect weak internal spring) and everything functions as it should! :)
 
Hi/Low switch acting as a cut out,??? All I can think of is there is problem in the loom possibly wiring chaffed and and shorting out, check around the head stock where there is a lot of movement.
 
Rusty2000 said:
Hi All,

2009 model, new problem not happened before. Bike starts fine but does going into gear. Won't start in gear either with no clicking from relays, just a dead starter. Is this a neutral sensor issue or a clutch cut-out sensor issue? Or is it entirely something else?
Click to expand...

Sorted now. New sidestand cut-out switch fixed it. The old one disintegrated on removal! Had to drop the sump to fit. Bad design or production engineer cock-up!
 
Hi/Low making the engine cut out was my problem.

Remover the switch over Christmas(actually it was easier than I thought to remove & disconnect), bridged the contacts on the plug and the bike has performed perfectly ever since. Am not even going to bother getting a new switch as it is fine as it is.

Looked at the old switch on the bench, it was corroded internally and only fit for scrap. Tested it and it was giving variable readings depending on how far the plunger was moved.
 
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