Gear position sensor

[thegasman]

Hi all,

Have searched forum and found similar problems, but not exactly the same, so for your viewing pleasure:

When starting up no gear or neutral indicator lights up, unless a little downward pressure on the gear lever is applied, and it won't start without this pressure. On starting doesn't show 1/N/2 but 3/4/5/6 ok until it warms up a bit, then everything works fine.

If I take the gear position sensor off, clean it up with contact cleaner, everything works great for a few days or so, then the problem recurs.

I have read elsewhere of packing the sensor unit with dielectric grease which might sort things out, but before I do this, thought I'd ask if anyone has had similar problems....and whether this is related to any other issue I am unaware of.

Associated but probably irrelevant information: bike has never started in gear, although I have noticed that the microswitch on the clutch lever only activated when pulling it right onto the bar. I have adjusted this, but haven't stalled when the bike is warm and gear indicator problems gone away to see if it's sorted. Occasionally bike jumps down a gear from 5th or 6th, but feels a bit stiff sometimes and I think I just need to clean up the linkage.

 

[The Prospector]

ACF 50

I had a similar problem on the morning I took the bike in for service, BMW quoted £400 to fix it (wtf) which I declined.
The bike will start without the neutral light being lit but you have to pull the clutch in but I removed the switch and sprayed ACF50 into every orifice I could and replaced switch, I also sprayed the wire connector plug and socket.
After a little test ride and a couple of waggles of the plug every thing came back to normal and has been fine since, which leads me to believe my problem was in the wiring plug/socket.
I must also say that ACF50 is a far far superior product to WD40 or similar and whilst expensive it is worth every penny IMHO.

 

[Rusty Bolts]

Similar problem here too. The position indicator plays up every now and again so I soak it overnight in acf50 and put it back on. I didn't realise it but my clutch micro switch wasn't working so I replaced that as well.
The problem seems to be preceded by damp/wet/cold days. Now the clutch micro switch is fixed it's not a problem, certainly not at £400

 

[Photoguy]

Clutch micro switch? There is one? I'm having problems with the gear indicator. I have never had to pull in the clutch lever to start the bike. -08GS

My problems are similar to the op's.

An independent has suggested a new sensor. (The one on the back of the gear box) Has anyone successfully managed a long term repair of this problem without replacing the part?

 

[trainman]

Clutch micro switch? There is one? I'm having problems with the gear indicator. I have never had to pull in the clutch lever to start the bike. -08GS

My problems are similar to the op's.

An independent has suggested a new sensor. (The one on the back of the gear box) Has anyone successfully managed a long term repair of this problem without replacing the part?

you can get them apart but to be honest the track which forms the variable resistor will be worn and any sealing up you do may only defer another failure, mine went about a year ago (06 bike), I would also say a mudsling or hugger is essential, the sensor and its cable get soaked otherwise.

mine always started without pulling in clutch too BTW

 

[Rusty Bolts]

Clutch micro switch? There is one? I'm having problems with the gear indicator. I have never had to pull in the clutch lever to start the bike. -08GS

My problems are similar to the op's.

An independent has suggested a new sensor. (The one on the back of the gear box) Has anyone successfully managed a long term repair of this problem without replacing the part?

If your gear position sensor is playing up the bike doesn't know what gear it's in and so won't start without the clutch pulled in. When my sensor played up I tried to start it with the clutch pulled in but as the switch was buggered it wouldn't start. Changed the micro switch and it's no longer a problem.

 

[thegasman]

There is a micro switch in the clutch. Next time pre start up pull the lever a few times and you should hear it clicking. Mine clicks but clearly needs replacing as I still cannot start unless in neutral, which can be awkward after a stall (thankfully a rare event).

I'll be interested to see if that sorts the sensor problems, but I suspect there two problems and I'll need a new sensor too, though may try packing with dielectric grease first.

sent via the modern interweb

 

[Bendy toy]

Mine wont start unless it's in neutral. I need a new clutch switch so really should get off my a**e and get one before the GB sensor plays up.

 

[Rusty Bolts]

There is a micro switch in the clutch. Next time pre start up pull the lever a few times and you should hear it clicking. Mine clicks but clearly needs replacing as I still cannot start unless in neutral, which can be awkward after a stall (thankfully a rare event).

I'll be interested to see if that sorts the sensor problems, but I suspect there two problems and I'll need a new sensor too, though may try packing with dielectric grease first.

sent via the modern interweb

From my experience it is two separate problems. The clutch micro switch issue only really became apparent when sensor played up.

 

[Photoguy]

That's great information folks. I have checked and can hear the click of the clutch micro switch. It's a bummer that I now seem to have two problems to fix but I only need to fix one in the short term?

I know a new gear sensor is £130+ (For the part) any idea about the clutch micro switch and ease or otherwise of that repair?

 

[Beemerman59]

Can't remember the exact price for the microswitch but from memory it was around the £20 mark. Its the same type used for the front brake switch (on my '08 anyway) so if you want to you can swap them over just to be sure. When mine gave up it was still clicking OK so thats not a definitive check. There's a small grub screw underneath that you loosen to adjust the switch (or remove) and a simple plug connection. Its a bit fiddly to do but easy enough.

 

[Photoguy]

Cheers Beemerman. That will get a looking at! The bike is becoming 'Unstartable' so that sounds very miuch like the first step.

 

[Steptoe]

There is a micro switch in the clutch. Next time pre start up pull the lever a few times and you should hear it clicking. Mine clicks but clearly needs replacing as I still cannot start unless in neutral, which can be awkward after a stall (thankfully a rare event).

That's great information folks. I have checked and can hear the click of the clutch micro switch. It's a bummer that I now seem to have two problems to fix but I only need to fix one in the short term?

I know a new gear sensor is £130+ (For the part) any idea about the clutch micro switch and ease or otherwise of that repair?

The clutch micro switch on the 1200 models is adjustable over a wide range.

If it doesn't work it's most likely to simply need adjusting.

"Check and adjust clutch micro switch" is part of my (the gsshop) 1200 service schedule.

 

[thegasman]

Did that, it now clicks on minimal movement of clutch, was previously only clicking when contacting the handlebar grip. Had read or heard from mechanic similar story to yours. Unfortunately made bugger all difference to mine, but that's not to say it won't work for someone else.

sent via the modern interweb

 

[Photoguy]

The clutch micro switch on the 1200 models is adjustable over a wide range.

If it doesn't work it's most likely to simply need adjusting.

"Check and adjust clutch micro switch" is part of my (the gsshop) 1200 service schedule.

Thanks for the info. I'll get a look at it asap.

 

[Photoguy]

Did that, it now clicks on minimal movement of clutch, was previously only clicking when contacting the handlebar grip. Had read or heard from mechanic similar story to yours. Unfortunately made bugger all difference to mine, but that's not to say it won't work for someone else.

So if it's clicking and still not working there's no point in adjusting as it's likely fecked?

 

[(RIP) Miff]

If I take the gear position sensor off, clean it up with contact cleaner, everything works great for a few days or so, then the problem recurs.

I have read elsewhere of packing the sensor unit with dielectric grease which might sort things out, but before I do this, thought I'd ask if anyone has had similar problems....and whether this is related to any other issue I am unaware of.

Contact cleaner will leave the sensor dry and free of any grease, meaning that any water can get in easier. As said previously, fill it with WD40 or ACF50.

When mine went doolally, I took it off, dried it on a radiator, then laid it on it's back and filled it with WD. It's been fine ever since.

 

[mikeyboy]

the switch is a lot easier to check and adjust on a gs911,as Steptoe suggested," part of the service"

 

[Neil A]

Clutch microswitch

Can't get my head around mine. My 04 GS has never started (in my ownership, which is 3 years) in gear with the clutch pulled in. You can hear the clutch microswitch clicking. I swapped it with the brake microswitch and the brake light still worked, so that told me it can't have been the microswitch which wasn't working. The bike still wouldn't start in gear, despite adjusting the switch so that it clicked as early as possible in the lever pull. I even adjusted it back the other way just in case, but no.

Thought about buying a new microswitch, but I had proved it wasn't that, so didn't, gave up and now only start it in neutral. It never seems to stall anyway.

I keep the gear change position switch/potentiometer thing spayed up with WD40, though!

 

[trainman]

Can't get my head around mine. My 04 GS has never started (in my ownership, which is 3 years) in gear with the clutch pulled in. You can hear the clutch microswitch clicking. I swapped it with the brake microswitch and the brake light still worked, so that told me it can't have been the microswitch which wasn't working. The bike still wouldn't start in gear, despite adjusting the switch so that it clicked as early as possible in the lever pull. I even adjusted it back the other way just in case, but no.

Thought about buying a new microswitch, but I had proved it wasn't that, so didn't, gave up and now only start it in neutral. It never seems to stall anyway.

I keep the gear change position switch/potentiometer thing spayed up with WD40, though!

is there not some interaction with the side stand switch, does your bike think the stand is down (ie s/stand switch u/or stuck)?