DISCLAIMER: The modifications described in the following text are for educational purposes only. In no way do I recommend that you apply these modifications to your own motorcycle. If you do choose to go ahead and modify your motorcycle based on the information in this document you will accept all responsibility for your own actions. The author(s) of this document, and host(s) providing it for you, accept no responsibility whatsoever. If you are unqualified to make any of the changes described herein but are bent on doing the modification, seek out a knowledgeable friend or professional mechanic for assistance.

Fitting an after-market clutch safety switch on a Yamaha TTR250

It's a very simple operation. All you need is a replacement switch, a couple of Japanese female bullet connectors and some heat shrink tubing.

The following pic shows the new switch compared to an original. You will see that the connectors are different and that the replacement switch is shorter by about 15cms.

 

Strip out the old cable and cut off a length of about 15cm.

 

Slip some shrink wrap on the new wires and attach the female Japanese bullet connectors to the old wires. An alternative is to solder the ends together.

 

 

 

Slip the shrink wrap over the joined connectors.

 

 

More shrink wrap over the joined connectors.

 

Finish off with electrical tape to tidy things up.

 

A little bit of work is needed at the switch end. Remove the old switch body by depressing the "latch" and pulling it out. Use a pair of pliers if its stuck in as it doesn't matter if it gets damaged!

 

The new switch has 2 latches and one is surplus and needs to be cut off.

 

The new switch then fits nice and snug into the clutch perch.

Job done - about 30 minutes tops.

Brian

Compiled by Brian Sussex, Devon, UK