After installing the ASV Clutch Lever and Perch, I noticed that the lever wouldn't pull all the way back when positioned for two finger operation -- the left hand control housing was in the way.

Also I had removed the turn signals so the turn signal switch was not necessary. (The State of Colorado does not require turn signals on motorcycles).

After searching the internet, I found that K&S Technologies produced a product that would both eliminate the obstruction problem and eliminate the turn signal switch. P/N 12-0050  I purchased this from PeakMoto for $23.95 plus shipping.

I started by mapping out the electrical connections between the new switch assembly and the bike's wiring harness using the information on the package and the KLX250S's wiring diagram. (Click on thumbnail for larger image)

Using some automotive type terminals, I clipped off the terminals on the switch assembly's wiring harness and soldered on the terminals (I don't trust the crimps).  Note that the blue wire is unused and will carry 12VDC when the headlight is on, I clipped the terminal off of it and folded the wire back up under the sheath.  (The blue wiring is intended for the rear tail light - I didn't bother with controlling its on/off function).

The terminals slide into the green connector behind the headlight. (The top unused row is for the turn signals)

Finished up the connection by wrapping it up in electrical tape. It's highly unlikely that this is going to vibrate apart.

One annoyance is that the horn button is labeled "KILL", so I just added my own label (who knows how long that is going to last).

Best of all there's no interference between the clutch lever and the new assembly ...and two added bonuses: I can slide the mirror further left and I now have a "OFF" function on the headlight.

Wednesday, October 22, 2008