Throttled Posted December 27, 2015 Share Posted December 27, 2015 (edited) 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 Quote Link to comment Share on other sites More sharing options...
Stu Posted December 27, 2015 Share Posted December 27, 2015 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! Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 Yes lever feels fine, the cable is OK and the other end at the engine casing moves freely. Quote Link to comment Share on other sites More sharing options...
Adam Posted December 27, 2015 Share Posted December 27, 2015 I'd be checking any wiring you might have disturbed whilst servicing the bike, could be another dodgy connection. Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 There is nothing visual and all lights etc work. So anything else along those lines would mean going to the dealers, via recovery. Quote Link to comment Share on other sites More sharing options...
Chrissb6 Posted December 27, 2015 Share Posted December 27, 2015 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 Quote Link to comment Share on other sites More sharing options...
mattycoops43 Posted December 27, 2015 Share Posted December 27, 2015 You disconnected the sidestand switch? It MAY need to be connected to earth or it thinks its permanently down. Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 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. Quote Link to comment Share on other sites More sharing options...
Stu Posted December 27, 2015 Share Posted December 27, 2015 So the bike won't select a gear whilst it's running? You may have a deeper problem! Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 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. Quote Link to comment Share on other sites More sharing options...
mattycoops43 Posted December 27, 2015 Share Posted December 27, 2015 clutch switch wires can normally be connected together at the switch to bypass. It shouldn't make it cut out while riding though. Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 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. Quote Link to comment Share on other sites More sharing options...
Stu Posted December 27, 2015 Share Posted December 27, 2015 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 Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 27, 2015 Author Share Posted December 27, 2015 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. Quote Link to comment Share on other sites More sharing options...
cockercas Posted December 28, 2015 Share Posted December 28, 2015 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. Quote Link to comment Share on other sites More sharing options...
Paul-Kent Posted December 28, 2015 Share Posted December 28, 2015 I had this on a ccm when I swapped stands over. I eventually shorted the circuit to make it think the stand was up Quote Link to comment Share on other sites More sharing options...
Throttled Posted December 28, 2015 Author Share Posted December 28, 2015 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. Quote Link to comment Share on other sites More sharing options...
Paul-Kent Posted December 28, 2015 Share Posted December 28, 2015 Get a circuit tester to see if it's feeding the plug Quote Link to comment Share on other sites More sharing options...
Throttled Posted January 15, 2016 Author Share Posted January 15, 2016 Turns out it was the side stand switch (again). The connectors were corroded and a quick file and clean and all has been fine. Quote Link to comment Share on other sites More sharing options...
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