Engage gear, engine cuts out.

[Throttled]

The Kawasaki KLE500, same engine as the ER5 and GPZ500. It has happened before and the culprit was the side stand switch thinking the side stand was still down and so on engaging gear it cuts the engine. This time it started to do it as I was riding along and if I changed gear it cut out on engaging the new gear. Now I cannot get it to engage gear at all and I have disconnected the side stand switch. It starts and runs fine having just been serviced by me with no apparent issues. Any suggestions?

EDIT - by engaging gear I mean when I have selected a gear with my foot and then release the clutch with my hand it cuts out.

Edited December 27, 2015 by Throttled

[Stu]

Gear lever action all ok?

Is it springing back to its correct position? If it's not then it won't select the next gear!

Although this should have no affect on the cutting out!

[Throttled]

Yes lever feels fine, the cable is OK and the other end at the engine casing moves freely.

[Adam]

I'd be checking any wiring you might have disturbed whilst servicing the bike, could be another dodgy connection.

[Throttled]

There is nothing visual and all lights etc work. So anything else along those lines would mean going to the dealers, via recovery.

[Chrissb6]

Sticking sidestand switch possibly? Check the switch is clean and that it moves freely, from there check the clutch and neutral switch. Fault is almost certainly a safety interlock problem

[mattycoops43]

You disconnected the sidestand switch? It MAY need to be connected to earth or it thinks its permanently down.

[Throttled]

I previously disconnected the side stand switch when it failed completely. It runs fine without one. I had fitted a second hand one, but after disconnecting it the bike will not engage gear.

[Stu]

So the bike won't select a gear whilst it's running?

You may have a deeper problem!

[Throttled]

I did not know there was such a think as a clutch switch and I see they are very cheap. It is too dark now, but I will check that tomorrow.

[mattycoops43]

clutch switch wires can normally be connected together at the switch to bypass. It shouldn't make it cut out while riding though.

[Throttled]

So the bike won't select a gear whilst it's running?

You may have a deeper problem!

 

I definitely selects first gear as I can feel the clunk and slight jerk, but when I try and engage the gear by releasing the clutch that is when it cuts out.

[Stu]

ah so it won't engage a gear as you release the clutch

it just cuts out!!

I thought you meant it wont select gears at all!!

I would just disconnect the side stand switch and if it solves your problem then you are in the right area

it could be a furred up connection shorting out

[Throttled]

I have edited the OP to make it clear I can select a gear with my foot, the cut out happens when I release the clutch lever with my hand.

[cockercas]

Thy cutting the wires to the side stand and joining them together.

It would let you change gear then because it thinks the stand is up.

[Paul-Kent]

I had this on a ccm when I swapped stands over. I eventually shorted the circuit to make it think the stand was up

[Throttled]

I took the clutch switch off. It works fine, but was very dirty inside, so I cleaned it up. Then it started to rain, so I will refit tomorrow. I have also noticed that a cable tie has been put on so tightly round the handlebar it has cut into the cable sheathing leading from the switch. So maybe the wire has corroded inside.

[Paul-Kent]

Get a circuit tester to see if it's feeding the plug

[Throttled]

Turns out it was the side stand switch (again). The connectors were corroded and a quick file and clean and all has been fine.