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Any reason this has this in it?

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Snipet
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Joined: 02 Apr 2012
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PostPosted: 19:12 - 04 May 2012    Post subject: Any reason this has this in it? Reply with quote

Hi guys and girls,
I'm asking for a bit of help again, Found a connector on my bike that has a paper-clip stuck in. and have no idea why.

The Story:
Got myself a lovely kawasaki zr7-s, but as i was sat on for the first time I noticed a wire that didnt seem to be doing anything:
https://farm8.staticflickr.com/7236/6996662162_585374c74c_z.jpg

I got hold of it and noticed it wasn't connected to anything, so I pulled it to the front of the bars:
https://farm8.staticflickr.com/7226/7142748277_35543a0fa9_z.jpg

It was then I noticed it had a bit of paper-clip shoved into two of the connections at the end of the wire:
https://farm8.staticflickr.com/7119/6996662150_5890e36931_z.jpg

The only thing I have found that this affects is the electronic ignition, when the paper-clip is in the wire it works (Only when the key is turned into the correct position). But when it is removed, it doesnt work at all.

This is a closer picture of the wire that splits, one into the handle (the choke wire?) and the other is this connector:
https://farm9.staticflickr.com/8147/7142745311_809a9bf8e5_z.jpg

Is this a simple case of a missing cap to the end of the wire and someone has bodged it so it stays a closed circuit. Or could this be something else?

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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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tbourner
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PostPosted: 19:15 - 04 May 2012    Post subject: Reply with quote

Is it supposed to go to the clutch lever? Has it had a new lever?

I'm only guessing.
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finpos
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PostPosted: 19:17 - 04 May 2012    Post subject: Reply with quote

It will plug in somewhere under the clutch lever.

Disabled safety interlock to stop you starting the bike with in gear, you need to have the clutch out.

f.
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DrDonnyBrago
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PostPosted: 19:20 - 04 May 2012    Post subject: Reply with quote

Just looks like someone has bridged the clutch switch.

Be wary of starting it in gear without pulling the clutch Thumbs Up .


Last edited by DrDonnyBrago on 19:21 - 04 May 2012; edited 1 time in total
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instigator
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PostPosted: 19:20 - 04 May 2012    Post subject: Reply with quote

finpos wrote:
It will plug in somewhere under the clutch lever.

Disabled safety interlock to stop you starting the bike with in gear, you need to have the clutch out.

f.


Thumbs Up I always disable mine too. Just leave it as is.
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Snipet
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PostPosted: 19:22 - 04 May 2012    Post subject: Reply with quote

I've had a look all around the lever and cant find anywhere it could plug into, Thats what's really stumped me. It just seems like a completely unused wire:
https://farm9.staticflickr.com/8157/7142746505_fc96146e10_z.jpg
____________________
First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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sickpup
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PostPosted: 19:26 - 04 May 2012    Post subject: Reply with quote

The clutch switch failed, they couldn't be arsed to replace it hence split pin.
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finpos
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PostPosted: 19:30 - 04 May 2012    Post subject: Reply with quote

Looks like the whole clutch switch is missing. The switch will be operated by that "D" shaped protrusion hanging down from the brake lever and will be attached by a couple of screws - think I can see at least one of the screwholes in the picture.

f.
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Snipet
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PostPosted: 19:32 - 04 May 2012    Post subject: Reply with quote

Thanks for the help guys, If its just a case of a simple bodge job then I don't have a problem with it. Guess I had better keep a stash of paper-clips on me at all times now, encase it falls out. Laughing Laughing
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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
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Snipet
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PostPosted: 19:40 - 04 May 2012    Post subject: Reply with quote

finpos wrote:
Looks like the whole clutch switch is missing. The switch will be operated by that "D" shaped protrusion hanging down from the brake lever and will be attached by a couple of screws - think I can see at least one of the screwholes in the picture.

f.



You sir have it spot on the money. The entire clutch switch is missing from under the lever. Now i know what im looking for, the exploded pictures in the service manual make alot more sense.
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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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pendulum
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PostPosted: 20:05 - 04 May 2012    Post subject: Reply with quote

I'm not sure I like that bodge, if it falls out the bike might not start or stop whilst running? Think I'd cut the connector off and solder the wires together, but that's just me.
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tbourner
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PostPosted: 20:07 - 04 May 2012    Post subject: Reply with quote

Why would you want to do that anyway? It's only for when it's in gear isn't it? Did it start if it was in neutral?
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Suntan Sid
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PostPosted: 20:08 - 04 May 2012    Post subject: Reply with quote

Looks like a good immobiliser!
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Snipet
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PostPosted: 20:14 - 04 May 2012    Post subject: Reply with quote

tbourner wrote:
Why would you want to do that anyway? It's only for when it's in gear isn't it? Did it start if it was in neutral?


The bike starts as if everything that should be there is still there. But if it comes out there is no way of starting the bike.
It doesn't cut the bike out if I take it out while its already started either, just looks like a clutch switch bypass.

But I have just this minute ordered a replacement switch which i will put on as soon as it arrives.
Does the switch just stop the bike starting unless you pull the clutch in at the same time? (To stop starting when in gear I suppose)
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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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instigator
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PostPosted: 20:17 - 04 May 2012    Post subject: Reply with quote

Why did you bother replacing it? Neutral Neutral
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Snipet
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PostPosted: 20:22 - 04 May 2012    Post subject: Reply with quote

Pulling the clutch in to start the bike up really doesn't bother me, I tend to do that any way most of the time.
But I think if that bloody pin comes out and I cant use the bike until I replace either the pin or switch it'll piss me right off.

It's just easier to replace the switch now and know that I wont have problems with starting the bike.
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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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finpos
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PostPosted: 20:30 - 04 May 2012    Post subject: Reply with quote

Generally with kawasaki you either need the bike to be in neutral or the clutch to be out, if either of these is true the starter will operate.

With that pin in place, the bike thinks it's always clutch out.

(N.B. clutch out = lever in!)

f.
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instigator
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PostPosted: 20:54 - 04 May 2012    Post subject: Reply with quote

Snipet wrote:
Pulling the clutch in to start the bike up really doesn't bother me, I tend to do that any way most of the time.
But I think if that bloody pin comes out and I cant use the bike until I replace either the pin or switch it'll piss me right off.

It's just easier to replace the switch now and know that I wont have problems with starting the bike.


The guy that done it is a bit of an idiot, you only require the two pins to make a connection which can be done with a tiny bit of wire with electrical tape keeping it in place or simply cut off the block connector and join the two wires.
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cornish
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PostPosted: 23:18 - 04 May 2012    Post subject: Reply with quote

Snipet wrote:
The bike starts as if everything that should be there is still there. But if it comes out there is no way of starting the bike.
It doesn't cut the bike out if I take it out while its already started either, just looks like a clutch switch bypass.


I had this exact issue with my kwack GT. Been stood for yonks and after replacing the battery got nothing from starting it on the button but it started and ran fine with a screwdriver on the relay. I have no electrical knowledge at all, but the two lovely people i tempted over with the promise of cake found the problem to be that switch on the clutch. They did a proper bypass thingie on it for me so i was a happy camper Thumbs Up
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Casper
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PostPosted: 23:23 - 04 May 2012    Post subject: Reply with quote

I an not that keen on this system. Just more to go wrong. I take it you got a waranty with this bike. Get the garage to sort it as yes that is the way people by pass the switch and the side stand but for a bike shop to sell you it like that is fucking shocking. When the come and pick it up tomorrrow for your fueling problem kiss ass with them.
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Snipet
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PostPosted: 08:41 - 05 May 2012    Post subject: Reply with quote

Quick update:
The garage picked the bike up this morning, and after warming the bike up a bit, showed the bloke the problem. He said the carbs need cleaning, as its been sat for a while he thinks a load of crap has gone down the fuel pipes and clogged it up (My first problem with the bike Sad)
I did mention and show him the clutch switch issue, which he did seem shocked about. But told him that i had ordered one and would fit it myself. I can get one delivered for £15, and I don't want the garage having my bike longer than needed while they wait for one themselves.

Don't have any problems with the garage though, very nice chaps and all willing to help. Plus getting £200 off the bike + £250 of free goodies with the bike that I shouldn't have, cause the ad was written wrong. Puts them in high standing in my mind to.
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First Bike: Pulse Rage 125cc Second Bike: Kymco KR Sport 125cc Third Bike: Kawasaki ZR7-S 750cc
Forth Bike Honda VFR 750cc Fifth Bike Honda NT650 Deauville Fifth Bike Suzuki GSX650F
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instigator
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PostPosted: 08:51 - 05 May 2012    Post subject: Reply with quote

Snipet wrote:
Quick update:
The garage picked the bike up this morning, and after warming the bike up a bit, showed the bloke the problem. He said the carbs need cleaning, as its been sat for a while he thinks a load of crap has gone down the fuel pipes and clogged it up (My first problem with the bike Sad)
I did mention and show him the clutch switch issue, which he did seem shocked about. But told him that i had ordered one and would fit it myself. I can get one delivered for £15, and I don't want the garage having my bike longer than needed while they wait for one themselves.

Don't have any problems with the garage though, very nice chaps and all willing to help. Plus getting £200 off the bike + £250 of free goodies with the bike that I shouldn't have, cause the ad was written wrong. Puts them in high standing in my mind to.


Glad you're getting it sorted but that's £15 wasted.
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