12s clutch lever starter interlock switch

[mfrane]

Off and on for the past several months I've had intermittent problems with the bike not starting while in gear with the clutch lever pulled. I knew there was a micro switch to allow starting and thought it must be faulty. Sometimes I could pull the clutch lever and release it allowing it to snap forward hitting the stop and then the switch would activate. Today it annoyed me enough to take it apart for inspection where I discovered that the switch actuator arm clearance to the clutch lever is adjustable. I removed the clutch lever, then removed the clamp from the handle bar allowing the housing holding the switch to be twisted around to expose the locking set screw (2mm allen) that holds the switch in position. I had to apply penetrating oil (Kroil is best) to the threads of the screw for a few minutes to get it loose. When the screw is loose the switch gap to the lever can be adjusted. The point on the set screw pushes against a small metal pad that is inserted into one of the switch mounting holes. Don't lose this tiny pad or you're screwed! I used some gasket cement to hold it to the switch for re-assembly. A mere 2mm of adjustment solved the problem. About a half hour job. Saved a trip to the dealer and service/parts cost.

[Droptarotter]

I had the same problem last summer...........and made the same repair. Very easy to do.....and yes, watch out for the little pad that will scoot to the far side of the shop.
Cheers