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82 GS650GL Clutch Sensor

  • Thread starter Thread starter exzachtly1
  • Start date Start date
E

exzachtly1

Guest
Hi all,
I have just purchased a 1982 GS650GL and one of the nagging issues (out of a few) I'd like to fix seems to do with the clutch sensor. I am completely new to motorcycles so please be easy on me :) I do have a Clymer manual being shipped to me now, so I suspect that will make things more clear but I figured I'd throw this out and see if anyone had an idea.

Basically the issue is that the bike will not start unless you pull the clutch in and UP. You actually have to pull the lever up very slightly in order to allow the bike to start. Works every time, but it bugs me because I know it's not right.

I understand that there is a switch within the clutch system that prevents the bike from starting unless the clutch is pulled in. I'm assuming it has to do with this. Any pointers on where to start looking?

Thanks!
 
Definitely something with the switch. Mine was bypassed by putting the wires together prior to going to a new aftermarket light switch unit. You could try cleaning the contacts if you can get it apart without loosing the spring that is in there. Good luck

Screw that Cylmer, download a FACTORY manual off Bikecliff's site. You can get a parts catalog while your there
 
Just connect the two wires to themselves in the headlight bucket and forget about it.

Eric
 
exzachtly1 said:
Any pointers on where to start looking?
Click to expand...
If you want to keep the switch, it is located under the clutch handle pivot. The easiest way to work on it is to remove the mirror, loosen the clamp just a bit and rotate the entire handle so the switch is on top. There are little bits in there that are spring-loaded, this way they will pretty much stay in place. Take all the parts out, clean them up well, put them back together with some dielectric grease.

If you would like the option of starting the engine without having to pull on the clutch lever, ignore the switch. Take the headlight out of its housing, find the yellow/green wires the come from the clutch switch and disconnect them from the main harness. Now take the two connectors in the main harness and connect them to each other. Put the headlight back in the housing, you are done.

.
 
Cool thanks. I'll probably be getting the wrenches out this weekend and I'll take a look. If it seems like too much of a hassle I may just bypass it as suggested.

I noticed that the bolt that holds the lever into the lever assembly is very loose. It's not tightened at all. Maybe intentional to allow the necessary "wiggle" that is currently required ;)

The locking nut is also missing from the clutch cable adjustor. I'll be trying to replace that too.
 
Given the condition of the clutch lever I'm thinking about ordering a whole new OEM clutch lever assembly. See the part here (part #57500-49301):

It's only $30. Has anyone used this website before? Is there a better place to get OEM Suzuki parts? Some of the bolts on the clutch lever are real rusty and beat up, along with the clutch cable itself; I will probably be replacing all of the cables with time too.

This way would kill two birds with one stone; fix the switch and have a nice, all new clutch lever.

Thoughts?
 
exzachtly1 said:
Given the condition of the clutch lever I'm thinking about ordering a whole new OEM clutch lever assembly. See the part here (part #57500-49301):

It's only $30. Has anyone used this website before? Is there a better place to get OEM Suzuki parts? Some of the bolts on the clutch lever are real rusty and beat up, along with the clutch cable itself; I will probably be replacing all of the cables with time too.

This way would kill two birds with one stone; fix the switch and have a nice, all new clutch lever.

Thoughts?
Click to expand...
That a good price, better than I thought it would be. No, I have never ordered from them before.
I wonder if it comes assembled, probably not.
 
gearhead13 said:
That a good price, better than I thought it would be. No, I have never ordered from them before.
I wonder if it comes assembled, probably not.
Click to expand...

Just in case you were curious - I ended up ordering this part from partshark.com and it DID come fully assembled. Not bad at all.
 
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