after market levers on a 2010 model - SV650.org

24-02-14, 07:20 PM

Well after fitting new levers to my suzuki sv650 and taking it out for its first run yesterday I found I had a problem. There is a Micro switch for the clutch lever to activate which was no longer working, basically the bike won't start without the switch being in the "out" position. This wasn't an issue as the new lever didn't have a tab to hold the switch in. However the bike began to stall when pulling the clutch in, huh!
A quick scout on the sv650 forum and it appears the micro switch sends a signal to the engine management system and this somehow dictates the revs once it's pulled in?

Anyway a little bit of thinking and I came up with this. The old lever is on the left clearly showing a large "tab" to activate the switch. A 3mm hole was drilled in the new lever,
I then shaped a stainless rivet and looped the end so there was a good contact point to push the switch. Epoxy resin bonded into place and a small piece of black shrink wrap and "voila" job done.
Hopefully this is the stalling issue and only time will tell now if it solves the problem. The bike has been fine up until fitting the levers so it does seem significant.

24-02-14, 07:25 PM

Tomor · 24-02-14, 10:34 PM

My Chinese levers came with a tab similar to the original lever to make contact with that switch. You sure your levers are for your model of bike?

Bibio · 24-02-14, 11:15 PM

never had a problem with the many sets of levers i have had from china. but i only buy from one place 'the2wheels'.

25-02-14, 07:24 AM

Yes i must admit i was surprised, they were from China and i did state the model year , must have just been unlucky

Never mind though problem solved

25-02-14, 03:53 PM

I have bypassed my clutch switch, they are prone to failing and cost £10 a pop !!

Tomor · 25-02-14, 04:22 PM

Is your bike FI Zipple?

25-02-14, 04:56 PM

Quote:

Originally Posted by Tomor

Is your bike FI Zipple?

FI ???

zipple ??? ha ha ha

Tomor · 25-02-14, 05:39 PM

Sorry couldn't remember your forum name as on my phone and it didn't show it! FI is fuel injected (k3) onwards.

PyroUK · 25-02-14, 07:01 PM

My chevers were from the2wheels and I have the tab missing too! Bloody pain in the r's!! Went to go start bike for work and it would go.

Seems like a reasonable fix for the issue!

24-02-14, 07:20 PM	#1
Gary1966 Guest Posts: n/a	after market levers on a 2010 model Well after fitting new levers to my suzuki sv650 and taking it out for its first run yesterday I found I had a problem. There is a Micro switch for the clutch lever to activate which was no longer working, basically the bike won't start without the switch being in the "out" position. This wasn't an issue as the new lever didn't have a tab to hold the switch in. However the bike began to stall when pulling the clutch in, huh! A quick scout on the sv650 forum and it appears the micro switch sends a signal to the engine management system and this somehow dictates the revs once it's pulled in? Anyway a little bit of thinking and I came up with this. The old lever is on the left clearly showing a large "tab" to activate the switch. A 3mm hole was drilled in the new lever, I then shaped a stainless rivet and looped the end so there was a good contact point to push the switch. Epoxy resin bonded into place and a small piece of black shrink wrap and "voila" job done. Hopefully this is the stalling issue and only time will tell now if it solves the problem. The bike has been fine up until fitting the levers so it does seem significant.

24-02-14, 07:25 PM	#2
Gary1966 Guest Posts: n/a	Re: after market levers on a 2010 model

24-02-14, 10:34 PM	#3
Tomor Member Mega Poster Join Date: Oct 2011 Location: Yateley, Hants Posts: 2,306	Re: after market levers on a 2010 model My Chinese levers came with a tab similar to the original lever to make contact with that switch. You sure your levers are for your model of bike? __________________ Yam XT125R - Sold SV650 -Sold DL 650 K6 - Sold 2012 Street Triple R - For Sale - Linky here

24-02-14, 11:15 PM	#4
Bibio Member Mega Poster Join Date: Jul 2008 Location: here as devil's advocate Posts: 11,561	Re: after market levers on a 2010 model never had a problem with the many sets of levers i have had from china. but i only buy from one place 'the2wheels'.

25-02-14, 07:24 AM	#5
Gary1966 Guest Posts: n/a	Re: after market levers on a 2010 model Yes i must admit i was surprised, they were from China and i did state the model year , must have just been unlucky Never mind though problem solved

25-02-14, 03:53 PM	#6
zippie01 Guest Posts: n/a	Re: after market levers on a 2010 model I have bypassed my clutch switch, they are prone to failing and cost £10 a pop !!

25-02-14, 04:22 PM	#7
Tomor Member Mega Poster Join Date: Oct 2011 Location: Yateley, Hants Posts: 2,306	after market levers on a 2010 model Is your bike FI Zipple? __________________ Yam XT125R - Sold SV650 -Sold DL 650 K6 - Sold 2012 Street Triple R - For Sale - Linky here

25-02-14, 05:39 PM	#9
Tomor Member Mega Poster Join Date: Oct 2011 Location: Yateley, Hants Posts: 2,306	after market levers on a 2010 model Sorry couldn't remember your forum name as on my phone and it didn't show it! FI is fuel injected (k3) onwards. __________________ Yam XT125R - Sold SV650 -Sold DL 650 K6 - Sold 2012 Street Triple R - For Sale - Linky here

25-02-14, 07:01 PM	#10
PyroUK Member Mega Poster Join Date: Feb 2011 Location: Poole Posts: 1,083	after market levers on a 2010 model My chevers were from the2wheels and I have the tab missing too! Bloody pain in the r's!! Went to go start bike for work and it would go. Seems like a reasonable fix for the issue! __________________ 2011 Triumph Daytona 675, Arrow exhaust and QS!

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