clutch switch problem

A couple of weeks ago, i started having starting issues with my bike. I had taken off the clutch & kickstand safety switches when i first got it. The clutch was easy, just pull the switch out of the housing & stuff the wires behind the headlight. The kickstand had to have a jumper put between the pins. I did this so i could easily reinstall them if i decided to sell someday.

Last year sometime, it started to act up. The bike would only start if put in neutral. I traced it to my jumper coming loose. I squeezed the clips, reinstalled it & taped it up. Everything back to normal.

But during our moab, kane creek death ride, it started acting up again. I assumed it was the jumper come loose again. We were pretty occupied, so i just had to shift to neutral every time to start. When i got up to my daughter's in ogden, i checked both connectors. The kickstand jumper looked fine.. but to be sure, i cut the connector & just spliced the wires together. The clutch switch seemed ok, so i just lived with it.. it still would only start in neutral.

Last night i tackled it again. I pulled the clutch switch wire all the way out.. had to lift the tank off to access the plug. When i shorted the plug, it would crank in gear, so i had discovered the culprit. Even though the clutch switch was neatly zip tied behind the headlight, somehow it got corroded inside, or mud or water had impeded the contact.. kind of strange, since the switch was not being used. I had manually pushed it several times & rechecked it, but it still was not making contact. It was an easy fix.. i snipped the plug, spliced the wires together, & plugged it back in.

If my switch went out with no use, i can imagine it going out with use, although repeated activity might have kept the contacts cleaner.. don't know. But if your bike will suddenly only start in neutral, the clutch switch & the kickstand switch are likely suspects. I understand why yamaha puts in that sort of thing, but it is unnecessary for me, so i disable it. I automatically pull the clutch before starting, or make sure it is in neutral if it is on the stand, anyway. The safety switches are just something to go wrong out on the trail, which they did! My more permanent splices should do the trick, & i don't anticipate any more issues with them.

A few more bike mods..

A few mods..

Since getting the ims tank, i've been tinkering with a few other mods, getting ready for next weeks ride in Utah.  Here's a few of them.

Radiator guard.  Flatlands.






LED tail light, brake light, turn signal combo.

I added this to the existing brake & tail light, but removed the stock blinkers.  I might add a couple more led blinkers later.

I re worked the light housing & plate holder & added a pipe standoff for my saddlebags.








Open up airbox more..

I don't know if it helps much, but i decided to open up the air box some more.. it didn't seem like the basic flapper mod gives more air flow, & i didn't see any reason to keep the whole top of the air box, if i was going to hack it up, anyway.  I would gain maybe an inch if i get underwater.. an event i seldom encounter, so i just took off the top.

I used a small drill bit to take out the plastic rivets.. i didn't drill them all the way down, just the tops.



Then i popped off the top with a small screwdriver.. no problems.



Pull it off.. no snorkel, but no restrictions, either.




I was able to put my alloy tire iron/wrench combos, a spark plug wrench, Tow strap, & a small bicycle pump with CO2 filler under the seat.  it doesn't block the air flow, & gives some useful storage.

Stebel Nautilus horn.
I loved my *loud* horn on my drz, so i kept it when i switched to the yamaha.  I had to split it.. the pump from the horn, but i was able to put it under the shroud.  I rewired, remounted it a couple of times, then ended up with the pump beside the radiator overflow, & the horn where the old horn was.  You can see it in the pics below.

Left side protection.

Since i decided to leave off the scoops & shrouds for a bit, i thought some better protection for the stuff on the left side would be in order.

I put in a couple of box aluminum struts from the frame to the bracket that supports everything on this side.



Then i made up a screen, & put an angle aluminum brace between the struts.  This attaches to the steel brace.







New tank panniers.. Kolpins.
I raised them up so my knees could slide under them when i slid forward on my bizarre but practical seat.



It's rough. it's rustic.  It looks like something out of Mad Max.  But it works & it's ready for next week's adventure!



scotty

IMS 3.1 gallon natural tank

9/7/10

Well, today the delivery person brought this:



It came with the instructions, cap & hose, the tank, & the scoop clips.  I read the instructions carefully.. in a nutshell, it says,

Step 1.
"Remove old tank".
Step 2.
"Install new tank".




I had to ride over to Cottonwood before the MVD closed for my son's truck, but it was open another 2 hours so i surely had time to put the tank on.

I pulled the seat, all the tank bolts, unclipped the wire connection (that was the hardest), & pulled off the fuel line.

The electrical clip has a snap that holds it connected on one end of the connector.  You have to pry up that snap then it pops off.

The fuel line has an orange slider thingy that slides to one side, exposing some blue tabs.  Push those tabs & the hose pops off.

Naturally, i had a full tank.  I poured it into a gas can.. got most of it in.  Then i took off all the parts on the old tank, put them on the new tank, & put it on.  It took me about an hour, but i didn't get the plastic on.. i had to ride!














I roared off to Cottonwood.. about 25 miles away, & barely made it to the mvd before they locked the doors.

I haven't filled it, yet, & unfortunately i put some gas in, so i won't know the total from empty.  But the reserve light came on when i got home.. probably still about 1 gal. in there, still.  I'll fill it up & see how much it holds from the reserve coming on.

Anyway, it took me about an hour.  Everything fit fine.. no fitment issues at all.  I got a little gas on me when transferring from the old tank.. run yours as dry as you can before swapping it out.  It will not drain out the bottom fuel pump assembly.  I had to pour it out the filler hole.

But i can see the fuel line on the tank.. it says it is '3.1' gal.  So this looks like a keeper.  I might eventually fabricate some other trim pieces.. i don't think we really need the wide scoops.  But without them, hot air blows right on your knee from the radiator.  Otherwise, i might stay with the 'mad max' look for a bit.

Minimal travel gear.. some thoughts on what to pack

I don't do a lot of solo riding & camping, but when i do, i like to keep it simple. There's something about getting away from other people & conversation.. words & other's thoughts. ..just the sounds of nature, & the bike when riding.

Our ears are inundated with noise, advertising, loud music, machinery, vehicles, etc. It's rejuvenating to get away with no sounds.. no noise.. just the quiet of nature & the great outdoors. Most of the time we are constantly interacting with family, work, media, etc. Alone & quiet we renew our acquaintance with ourselves & the great unknown. Mystery & eternity re-introduce themselves. Our minds & souls are renewed. Our focus on life restored.

Not much is essential.

As far as travel gear goes, i decided if i wasn't using something almost every day, i could manage without it. It does show us what we really need, & what we think we need. In the past, i took too many clothes & other stuff. It's easy to wash things when stopped, & out west, they will dry out quickly, especially if i bring more poly stuff.. socks, underwear & shirt. I wash them, then they're ready to wear in the morning. If there's no water around, i don't wash things.

I'm also not into lots of cooking when travelling on the bike. If there's not a local cafe around, you can always get something at the gas station. Anyway, i've found i enjoy riding with less.. i'd rather be lighter when i get into tough terrain than weighed down with a bunch of unnecessary clutter. Maybe i'm trying to get away from all my clutter at home.. years of hoarding have complicated my life with too much junk. When i ride, i leave it all behind.. part of the isolation therapy that solo riding provides.

I basically have my riding gear that i wear. I wash it when stopped (undershirt, socks, underwear, etc). I have some 'civvies' for going out or even when camping. Nylon pants, shirt, sandals. Hat & mosquito head net are nice in buggy spots. Here is my travel package list:

Ride gear:
Helmet, gloves, boots.
Mesh riding jacket with rain cover (slips in zippered back pocket).
Riding pants, knee guards.
poly underwear, underarmour type t shirt, coconut socks
Long sleeve fleece shirt & pants if cold weather traveling.

Nylon pants, long sleeve nylon shirt, flipflops, hat, head net.
sleeping bag, hammock (doubles as ground cloth), tarp for rain cover.
Camera, cell phone, gps, chargers, wallet.
Water bottle, snacks, sun block, whiskey flask(optional!)

Small tool kit, tire irons w/wrenches, patch kit, bicycle pump, zip ties, elect. tape, first aid kit, folding lock blade knife, flash light.

I have my first aid kit (which is the one thing that has increased) in a number plate bag. In it is also a string type sack/backpack in case i have to walk some distance carrying stuff.

Everything fits in my tank bag & the 2 panniers. I put the sleeping bag, tarp & hammock in a tail bag. Everything weighs less than 20#.. probably closer to 10 without the tools. The point in having a light weight bike for travel is being light weight. If you pack 100# of gear on board, you might as well get a bigger bike to haul it.

I've not had problems with bears or other wild animals.. hopefully it will stay that way. I camp pretty close to the bike, & i have an air horn on it, so i hope if some woodland creatures were scoping me out, i could let out a blast from that horn to discourage them, somewhat. Other wise, i'm left to chucking rocks at them, poking them with sticks, then a knife vs. teeth fight if all else fails. I'm pretty fearless around animals.. they have a sense of that & usually leave you alone. Usually.

I prefer the simplicity of not cooking. You have to stop for gas every so often, anyway, so i refuel myself then, too. When travelling i usually only eat 1 or 2 big meals a day. I'll have some jerky or trail mix in my bag for snacks. I fill my water at the gas stops, & get a gatorade or soda.

A hammock isn't all that comfortable.. if there are some thick leaves or grasses around, i prefer to lay the hammock down as a ground cloth & put the bag on that.. especially if it's cold. Hammocks are notoriously cold without a sleeping pad. But if you're carrying a sleeping pad, you don't really need a hammock.

It's always a work in progress.. i don't obsess about it. I just try to keep it simple. Part of 'getting away from it all' is the simplicity of things. With less to manage or think about, i have more freedom for deeper philosphical musings.. or wondering what i'll have for my next meal.. always a highlight!