Getting frugal in my old age

[FuzzyWuzHe]

So my 08 Gl1800 has not been starting in gear with the clutch engaged. Isolated it to the clutch micro switch. Removed it, cleaned it with contact cleaner and put it back, NADA.

Removed it again, left the wires hooked up, when pushing the contact, the trike starts in gear. Hmmm .. so the switch works but not engaging enough. No obvious wear on the switch or the clutch where it engages.

Decided to take the switch apart and bend the contact arm just a tad to get it to engage sooner. Took it apart, bent the arm and was putting the cover back on when the innards jumped out of the switch (dang spring). As I did not plan to take the innards out, I didn't take a good look at them or even take a picture. I did get it back together and now all is well.

Took me 30 minutes to find the spring, and 3 hours to figure out how the innards went together (there are only 6 pieces and the case) and get them back together. Plus about 30 minutes to remove, clean, install, remove and reinstall the switch.

So, if you use my pool service rates ($70/hour) it cost me $280 to "repair" the switch. Out of curiosity, I called my dealer to see if they had one and if so how much.

Of course they did have one and it costs $17 and change. I did purchase it as a spare.

I figure I got $263 worth of satisfaction in a job well done. (i figure the frustration and self flagellation were free, like James says, consider it all joy.)

[GoldWingrGreg]

Part #6 http://www.partzilla.com/parts/searc...DER/parts.html

WOW ... now that is frugal You could have saved yourself hours of labor by just buying a new switch. They're about $14. However, I'm sure it was a fun project. Other likely causes are:

- aftermarket clutch lever

- worn clutch lever/pivet bushing

- aftermarket fat grips

- worn pivet pin

- clutch lever adjustment needed

This is probably a good time to talk about lever maintenance.

If the lever has more then 3/8" of up/down movement, the pivot pin and sometimes the bushing is worn. Around here both are common replacement parts. Once the lever is out, be sure to look at the rod that it pushes on, the boot at the back of the m/c around the rod could be torn. Also, the brass bushing the rod fits in, inside the lever is often galled. If so, the lever can be too. Levers, pins, rods, and bushings should be lubed every 8k with silicone paste. Be sure to do the same to the brake lever.

For proper clutch lever adjustment > Owner's Manual > Index > clutch system > clutch lever adjustment.

[Peter A.]

I'd say that a job well done and a GREAT learning experience - thanks for the input!!!