A used clutch lever assembly arrived, from e-bay, in today's post. Well, for 9 quid it'll be a useful spare and I fancy doing a blue set for my blue solo.

Now, have you ever tried to remove the clutch switch without destroying it?
This one was pretty tight and after soaking with WD40, flat pliers still didn't make an impression on it.

The switch hexagon is 11mm AF and there's no way a normal box spanner (even if I had one!) will go over the connector to reach the hex.

My solution was to cut a short length of tube, about ½" bore and flatten the end in a vice to a bit less than 11mm. I then filed the end to make a two sided spanner.



This then slipped over the connector, along the cable to reach the switch.
I had to grip the tube in the vice to get enough grip to undo the switch so maybe I'll drill a hole for a tommy bar in case I ever need to remove a switch while it's still on the bike.



There may be a proper tool for doing this, but if you're stuck this tool is pretty easy to make and it may save a few curses.

Cheers,
Paul.

That IS a very thoughtful solution. Particularly that you gripped it on 2 opposite sides.
Using an open end wrench will ruin the switch almost every time. but I see you can't even get that in there. When I put my new switch(s) in my rs, I used anti seize and only barely tightened them just enough to prevent them from vibrating loose.
GREAT Job!


Regards, Ibj...

ibjman wrote:11mm tubing flare nut wrench, about $12

That'll never get into the recess.

Paul.

You're quick, paul.........you corrected me faster than I could post a corrected edit.

top job scp .... that one sliped by me for one ...

If you don't mind a bit of a hassle, this can be done with (somewhat) standard tools.

I just changed one on my 1998 RT.....same set up....switch is buried deep into the recess in the casting.

I chose to disconnect the switch harness lead at it's harness plug connector and remove the individual wire spades from the plastic connector. It takes a special probe to release the wire spades from the plastic connector and it takes a bit of patience to get them out without damaging the retaining tabs that hold them secure in the connector.
  Once the individual wires are free from the plastic end, I just slip a 3/8" drive 11mm deep socket over the wires and thread it down the wire to the switch. Install the deep socket over the switch and turn it loose with a pair of vice grips.

I think it's a toss up as to which might be easier for some folks. Making the suggested tool above or extracting the wire spades.
 Just an additional point of view.
Regards, Ibjman

This is a job for an 11mm box spanner - I have at least two in my garage. There is also another choice it is a full hex spanner with a hole through the end and a right angle. Not sure what the name is but in 25 years of Aircraft work I had never seen one before. I left the UK and came to France and you can buy them everywhere. I'll try and find a picture.

This is the beast. They come in a set with 8, 10, 11, 13, and 17mm. You can also buy individual one of all the sizes in between.
This one is a bi-hex, but I only buy the hex ones. There is a hex in each end and the one in the short bit has a hole all the way through for taking nuts off long studs.

The French have strange tools because they make strange cars.

BMW do make a tool for the job http://www.ebay.com.au/itm/BMW-Heyco-10-11mm-Tube-Spanner-Tool-Genuine-Used-/330899087535?pt=AU_Car_Parts_Accessories&hash=item4d0b1f60af

RicK G wrote:The French have strange tools because they make strange cars.

And they make aeroplanes too........... That's why I fly Boeing. 

I wonder why Zee Germans don't make aeroplanes? 

There was something about not making them in the surender deal at the end of WW2 or at least I think it was WW2, it may have only been WW1.  Thw WW1 deal was what turned BMW to making motorcycles and not producing anymore planes

Ze Fokkers started in the Fatherland - the original flying bricks!

And the jet engine was invented in England. The first jet airliner was English.
The French did not do too bad either. That symbol of Americanism, the statue of liberty was made in France.

I thought Fokker was originally a Dutch design? 

Did zee Germans lose in both WW1 & WW2?  Hmmmmm... Interesting.  Maybe the K bike was their next attempt at world domination.

TacKler wrote:I thought Fokker was originally a Dutch design? 

It/he was. Fokker tried flogging his designs to the British but when he failed to interest them, he went to the Germans.

About 3/4 of the time you can get the clutch switch out using needle nose pliers.

Elegant solution once again SCP