Hi guys, Tonight I removed the clutch lever and installed a new one. I unplugged the Master Cylinder (I think that's what the manual calls it) plug and cleaned it up as well. When I got everything put back together I tried starting up the bike and nothing. When I push the start button it doesn't turn over or anything. The battery is at a full charge so I'm assuming I messed something up with the plug on the clutch lever. Any and all ideas would be much appreciated. 2005 TE510
Help!! Bike won't Start....... Hi guys, Tonight I removed the clutch lever and installed a new one. I unplugged the Master Cylinder (I think that's what the manual calls it) plug and cleaned it up as well. When I got everything put back together I tried starting up the bike and nothing. When I push the start button it doesn't turn over or anything. The battery is at a full charge so I'm assuming I messed something up with the plug on the clutch lever. Any and all ideas would be much appreciated. 2005 TE510
Had the same thing a while back on my 610. But on the RH side after i had moved the position of the throttle clamp--loosened it and tied it tight again with a spanner --started must have a earth or something that was not making contact on the handlebars--
If it is a clutch lever not specifically for a Husky it may not be depressing the clutch safety switch. I installed a KTM shorty lever on my bike then drove 10hrs to the NE Husky Gathering to find it wouldnt start. Thought it was the solenoid the whole time till I got home and tested it and found that it has to push the switch in. My other bike is the opposite, when you pull the lever it releases the switch and I thought the Husky was the same way. I would try pushing that switch in with something and try the starter again. If that is the problem, you can follow those wires from the switch down to where they connect under the tank and unplug the switch, remove it and then connect the two wires coming to the switch. At least that worked on my 07, I think yours is the same.
Check the connection of all wires going to it. There is a switch there so that you need to pull in the clutch to start the bike so your don't start it in gear.
It is also not uncommon to connect the 2 wires that connect to the "plug" to each other to circumvent the clutch safetey feature. Joe
Yes connect the clutch switch wires together to see if that is your problem. You also might have pulled a wire connector apart behind your head light. (lots there) If it turns out to be more than that and you're not convertible with wiring. You better get some help, someone that can run a multimeter and start tracing.
Ok guys here is what I figured out today. Here is what it looks like with the clutch lever removed. The small, black middle "button" is what needs to be pushed for the starter to engage. When you compare the new lever with the one I bought from MotoPlasticsUS.com, you can see that the stock lever (on the right) has a small notch on it that engages the "button". So now what are my options? I've got some guys at work with welders. I was thinking maybe they could weld something similar to the new lever. I'd rather not mess with the wires and keep the stock setup as much as possible. Thanks again everyone!!
Whoooooooooaaaaa! STOP. Way too complicated. You want to get rid of the clutch "safety" switch all-together. Just find the connector, unplug it, cut the wires, twist them together and tape. Then take the switch end out of the clutch lever - save it in case you ever need a left-hand-rear-brake switch - otherwise, toss it. Done. The clutch "safety" switch is dangerous, stupid, and expensive - in other words, lawyer-created.
+1... don't make it more complicated than it needs to be.. On my 610 I just followed the wires, to behind the headlight, unplugged and simply plugged the two connectors together. Follow the advise of the past two posts and the MANY before, just disable the "lawyer switch"..
+2 I never had to cut any wires on mine, just follow the switch wires down to where they connect to the harness, unplug switch and connect the wires with the factory connectors.Then you can remove the switch and keep it if you want. I tried welding my old lever after I cut it down to make it a shorty. The lever isnt a very good alloy and is prone to cracking after you weld on it.
