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Discussion Starter #2
Tried some contact spray and wd, sandpaper on plug on the stand , nothing for now. I can see some corrosion on the pins.

I can't unplug the clutch lever plug. I dont know if I need to press something or unscrew but it seems like its plug and play jack.
 

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The clutch switch does have a tab you need to press to disconnect the wire connecter. But you would need to remove the 2 screws holding the switch in and remove the switch first, to be able to disconnect the wire.


Can't really offer any info on the side stand switch, as I have never had an issue with that one. I was going to suggest to just get a new one as I'm thinking they are probably not expensive. But I can't even find the side stand switch on the parts page. :surprise:
 

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27010-1467 s/s switch $54.53 on ronayers.com shows fitting 2003-2009 US models, can't vouch for Euro application

27010-1185 on 87-98 about $28 bucks

before buying, suggest use your multimeter to verify wiring and switch integrity

When you're done, bring the meter over to my place, we'll wear it out workin' on this thing :grin2:
 

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@ducatiman Can i ask what page you found that on. I couldn't find that switch to save my life. :surprise:

FYI I thought it would come in at about $20, like the clutch switch.
 

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Discussion Starter #8
There is sidestand switch on wemoto.

Btw tonight I came home, in the garage still in 1st gear, clucth pressed, slowly put sidestand down and engine shut off. Tried 2 times, faster, nothing, let the clutch, nothing. Tried again, putting side stand slowly and at some point kills the engine. So its not wirring I guess, probably side stand switch mechanism not working properly cuz of the use/dust/water etc. But its working. Im gonna try something more to get it working 100%
 

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Discussion Starter #9

The clutch switch does have a tab you need to press to disconnect the wire connecter. But you would need to remove the 2 screws holding the switch in and remove the switch first, to be able to disconnect the wire.


Can't really offer any info on the side stand switch, as I have never had an issue with that one. I was going to suggest to just get a new one as I'm thinking they are probably not expensive. But I can't even find the side stand switch on the parts page. :surprise:
I will maybe try to take it apart but dont think so, dont want to mess up with that clutch switch, also heard that that plunger/pin is prone to cracking...

There are side stand switches on motopartseu and wemoto I think but its more expensive than that clutch one. 40-50 euros
 

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the switches are easy to test. takes all of 2 mins. sit on bike with side stand down. start engine. pull clutch. engage 1st gear. slowly release lever.

if the bike cuts out. the side stand switch is working. if the bike continues to run it's not working.


clutch switch. while still sat on bike engine stood engage 1st gear. ignition on. press starter. nothing happens. starter won't operate. pull lever. try again if bike starts. the clutch switch is working. on one circuit. to test the other circuit. while the bike is running and in gear lever pulled drop the side stand. if nothing happens the other circuit is working. however if the bike stops when the sand goes down even if the lever is pulled the second circuit is faulty.


it seems yours does this from your post so it is the second circuit on the clutch switch. isn't working. check for bad contacts first but it's easier to just change the switch than take it apart.
 

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Discussion Starter #12
" to test the other circuit. while the bike is running and in gear lever pulled drop the side stand. if nothing happens the other circuit is working. however if the bike stops when the sand goes down even if the lever is pulled the second circuit is faulty. "

Dont know what you mean by second curcuit but will google for it.
 

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" to test the other circuit. while the bike is running and in gear lever pulled drop the side stand. if nothing happens the other circuit is working. however if the bike stops when the sand goes down even if the lever is pulled the second circuit is faulty. "

Dont know what you mean by second curcuit but will google for it.


the safety switches are in a circuit that works with a combination of on and off's depending on which switch is deployed or not.


the neutral light is part of the circuit. when it's on. [in neutral] all the other switches are ignored and so mute. only when it's off do the others actually do something.
the side stand switch is a simple on/off switch to let the system know when the stand is down.

the clutch switch however is a two way switch [with 3 wires] it is never off [except in neutral] when the lever is pulled it operates one circuit when the lever is released it operates a different circuit.

depending on what position the other switches are in will determine what the bike does.

assuming the bike is in gear. the starter will not operate with the clutch out. this is to stop you starting it in gear, [one circuit] but if the clutch lever is pulled. it will let the starter operate. [other circuit] this is so you can restart the bike if stalled without the need to put it back into neutral.

this switch also works in conjunction with the side stand switch. if the stand is up either position of the clutch switch, will make no difference. [normal riding] but if the bikes in gear and the stand is down releasing the clutch cuts off the engine. this is to prevent you riding off with the stand down.

you can test this as I stated. you can also test the circuits while riding [not recommended unless your on a quite road.


start the bike as normal set off slowly in first gear when you reach 10mph move the side stand switch with your toe the bike will cut out. while rolling press the starter. nothing should happen. then pull the clutch the bike will now restart.
 

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Discussion Starter #14
Ok now tested , its not shutting off the engine while pulled and side stand down.

Plunger on clutch switch is working, but maybe I think that my clutch lever is far off and not touching the plunger when Im releasing the lever???

Also Im using this guide https://faq.ninja250.org/wiki/Cleaning_and_servicing_the_clutch_switch but its not the same.

Can I just unscrew those 2 philips screws and took it of (also unplug it first)? There are no those 2 https://faq.ninja250.org/wiki/File:2011-06-12105141.jpg screws on ex500, mine is only 1 and its near some metal part and I cant put the key there (metal part is preventing it). And really dont wanna unscrew those allen screws and took whole left assemble down...
 

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Discussion Starter #19
cant i simply test clutch switch like this:

side stand down, 1st gear, clutch pulled in-with the right hand press the plunger from the switch in. That would be the same thing as clutch lever released. That should kill the ignition?
 
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