Starter issues due to gear sensor, I believe

[joemaniaci]

So I am having intermittent start issues and I am curious where to look to solve it.

Most of the time if the bike is in 1st I can't start it.

Most of the time I can only start it in neutral, but only when I do NOT have the clutch handle pulled in.

However, once started, I can 99% of the time shift to 1st without it dying.

Question though: I can't remember if I should be able to start it in first, with the kickstand down, so long as the clutch handle is pulled in.

Once it is started, and after I have shifted to first, if the kickstand is down and I let off the clutch, it dies as expected.

The kill switch is operating as normal, but I noticed when I switch it to Run, my tachometer blips a little bit.

Does this help narrow down any sensors/switches/relays? Any other combinations of control manipulation I can use to narrow down the problem?

I feel like if I don't mess with the kickstand, clutch, or anything else, that rolling the bike forward/backward(while repeatedly hitting start) finds a sweet spot and it starts.

[cushman eagle]

It should start in any gear with the kickstand down or up, if the clutch lever is pulled back.Does the neutral light always come on if it is in neutral?I am wondering if you have the broken wire in the ignition switch harness syndrome.My '99 already had 2 wires jumped around breaks, when I bought it at 22000 miles.

[joemaniaci]

It should start in any gear with the kickstand down or up, if the clutch lever is pulled back.Does the neutral light always come on if it is in neutral?I am wondering if you have the broken wire in the ignition switch harness syndrome.My '99 already had 2 wires jumped around breaks, when I bought it at 22000 miles.

Neutral light is on/off as it should be when switching gears. I don't even know where to start looking if I need to tear things apart. Where is the sensor for detecting you're in neutral anyway?

[cushman eagle]

One of our members has posted a repair manual online, you can download,which will help you with your diagnosis.At the present time,I do not remember how to find it.I bought a hard copy when I bought my bike,and with ,it plus members help, I have been able to do my service,repairs and upgrades.

[Me Again]

So I am having intermittent start issues and I am curious where to look to solve it.

Most of the time if the bike is in 1st I can't start it.

Most of the time I can only start it in neutral, but only when I do NOT have the clutch handle pulled in.

However, once started, I can 99% of the time shift to 1st without it dying.

Question though: I can't remember if I should be able to start it in first, with the kickstand down, so long as the clutch handle is pulled in.

Once it is started, and after I have shifted to first, if the kickstand is down and I let off the clutch, it dies as expected.

The kill switch is operating as normal, but I noticed when I switch it to Run, my tachometer blips a little bit.

Does this help narrow down any sensors/switches/relays? Any other combinations of control manipulation I can use to narrow down the problem?

I feel like if I don't mess with the kickstand, clutch, or anything else, that rolling the bike forward/backward(while repeatedly hitting start) finds a sweet spot and it starts.

I am not the Guru ,but it sounds like the clutch switch is bad.
If it starts fine in neutral and kickstand switch is working ,it is not the safety switch.
Try spraying a little WD40 or some other lube (a silicon based or dry lube may be better) and work the switch a few times ,then try again.

[joemaniaci]

One of our members has posted a repair manual online, you can download,which will help you with your diagnosis.At the present time,I do not remember how to find it.I bought a hard copy when I bought my bike,and with ,it plus members help, I have been able to do my service,repairs and upgrades.

Had it already downloaded, all it says is in the troubleshooting section was that it was a possibility. Not how to absolutely diagnose. I think the chapters that the guy posted are incomplete, but it also wasn't the supplemental.

EDIT: Looking more closely at page 15-21, it looks as though the Starter Lockout Switch is open/closed depending on the side stand switch, and the neutral switch. Side Stand switch is easy to look at, but where is the neutral switch?

[sheiserman]

Lower left side, down by the sight glass.

The book calls it "neutral and overdrive switch", and shows its location on page 15-41.

[joemaniaci]

Never mind, I'm an idiot. It was the clutch safety switch that was the problem. I still can't believe cleaning it out fixed it considering what the symptoms were.