Cleaning and servicing the clutch switch

For checking the switch, see here and here.

The clutch switch is a simple contact plunger switch. When exposed to dust and the elements, it can get clogged and grimy. If the contacts get clogged up with dust, the clutch switch could stop working. Most of the time, it just starts making really annoying grinding sounds and the switch starts offering resistance to the motion of the clutch. But if you get enough guck in the switch, the bike won't start with the clutch pulled in.

First, these two screws hold the switch onto the perch. Remove these to take the switch off. This is common to the EX250, EX500, and the more common ZX-6R parts. These fit on the 46076-1165 perch, and most likely others.

The switch is only held together by the plastic clips on the housing. Here is one on one side.

And these two on the other side. These clips lift up by fingernails. A small screwdriver will also do it. Really, this should pose no trouble.

After the clips are pushed up, just lift up the housing.

And here is the housing wide open. The plunger is on a spring on the left. The right hand side has the contact plates.

Total parts are: 2 plastic case housings, 1 plunger with electrical wiper, 1 spring for the plunger return, 3 electrical track-style paths for the wiper to contact and the electrical connector. Use a small toothbrush and clean off the grit and grime, then move to a soft wire brush to de-corrode the electrical traces. Finish up with a pencil eraser. After the electrical contacts are clean, apply a small amount of dielectric grease to the traces, the wiper, and inside the electrical connector.

Put the plunger back in, and lube the back side of the plunger (the side that contacts the housing) with some synthetic lube. While mostly a placebo, the lube should make the motion of the plunger smoother. The front copper contact should remain clean from the lube.

Putting it back together is just snapping the two halves together and then screwing the switch back on. That's it.