Broken Clutch Lever

[kingpinn]

I new it would happen sooner or later.

My son and I were taking turns riding the DR in the woods about 2 miles from home when he crashes going like 5 -10 mph and breaks the clutch lever. We figure if we can engage the clutch the bike should start. After many tries we realize there is a small wire going into the clutch assembly near the perch that must be a relay of some kind telling the bike the clutch is engaged. We then removed the broken piece, from the perch engaged the clutch and the bike starts. Leeson learned, I bought two clutch levers and stashed one in the tool case.

[sw3dl1]

That small wire is the clutch safety switch, there's also one on your kick stand. Their function is to keep the starter from engaging unless the clutch is pulled in and the kick stand is in the up position. Most people remove both of them and wire around them to avoid the problem you just encountered. The procedure to get rid of them is listed in this thread someplace, if you can't find it here go to advrider.com and use their search feature as well.

[LukasM]

+1. Disable both, KISS and less pieces to malfunction.

You shouldn't give the keys to anybody stupid enough to start the bike in gear without the clutch anyway. ?

[NVDESERTKID]

Get some good bark-busters (with some kind of metal frame) and forget about ever having to replace a lever or throttle tube.

You can also chop the clutch shorter into a 2-finger sized lever... nothing to break off.

[kingpinn]

NVDESERTKID ,

I did chop the lever shorter this time.

I have Moose bark busters, I just had them positioned wrong at the time.

The DR is my do it all bike, commute, woods, road rides. What a great bike!!