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Finally got the K1200LT back together for the riding season after a clutch replacement. Was really happy when it started back up and after 1 or 2 seconds of rough idle, just quieted right down to what I expected. As I was getting ready to push it off the center stand, I noticed that the gear position wasn't showing on the dash. I shifted through the gears and it seemed that neutral light wasn't working between 1 and 2, although the notch was still there. The light does briefly come on during the 3 to 4th gear shift.

I pulled the bike apart enough to get to the sensor. I cleaned it and the connection point and verified that it was snapped into place on both ends.. Still nothing and the weird neutral light issue. Before I drop $150 for a new sensor, does this sound right or could I have messed up something inside the transmission?

-Kris
1999 K1200LT - 57,000 miles.
 

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Finally got the K1200LT back together for the riding season after a clutch replacement. Was really happy when it started back up and after 1 or 2 seconds of rough idle, just quieted right down to what I expected. As I was getting ready to push it off the center stand, I noticed that the gear position wasn't showing on the dash. I shifted through the gears and it seemed that neutral light wasn't working between 1 and 2, although the notch was still there. The light does briefly come on during the 3 to 4th gear shift.

I pulled the bike apart enough to get to the sensor. I cleaned it and the connection point and verified that it was snapped into place on both ends.. Still nothing and the weird neutral light issue. Before I drop $150 for a new sensor, does this sound right or could I have messed up something inside the transmission?

-Kris
1999 K1200LT - 57,000 miles.
First question would be did you take the transmission apart in order to press any seals out from the inside or to replace any input/output bearings while you were doing your clutch?

That sensor has a half moon one way fit If the picture on MAX is correct. It can only go on one way. Check the connector and make sure no pins have pushed back in or are bent. I am not sure how to test that sensor or what inside the transmission could be oriented wrong but you would have to have taken something apart to have gotten it together wrong.
 

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Discussion Starter #3
I didn't open up the transmission, just replaced the seals around the clutch as those were the ones that went bad.

I will try pulling the sensor again and cleaning it. Just seems odd that it was working prior to working on the clutch.. Worst case, I'll order a new sensor.

Thanks for the help
-kris
 

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I had an issue with my gear indicator displaying the incorrect gear (2000LT) and JohnZ attached a diagram and responded with the following:

"Sounds like the gear indicator switch is getting dirty. On the LT there are 3 switches that send a coded signal to the dash looks like you are missing the third switch or its contacts are dirty."

Hope it helps,

Rob
Navarre, FL
 

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I didn't open up the transmission, just replaced the seals around the clutch as those were the ones that went bad.

I will try pulling the sensor again and cleaning it. Just seems odd that it was working prior to working on the clutch.. Worst case, I'll order a new sensor.

Thanks for the help
-kris
Just replaced mine as I destroyed the old one during a clutch repair. Found it on e-Bay for $25.

Not sure it can be cleaned - if you pull the cap off the SMALL springs holding in the pins that made contact with the switch assembly like to shoot across the room.

I have some pics of the internals of the switch if interested - will post when I get home.

Is it seated all the way down? That is, are both sides of the spring clip under the mounting bosses?

edit: added pictures...

Note the three small contacts and springs - these fit into the rotating assembly (three small holes) which in turn connect to the head assembly (one with wires attached) - these are the three connections shown in the wiring diagram above (plus ground). This one has 122k on it and I don't see that it's dirty. I also don't see any keying marks to get this aligned back together correctly - it may not matter based on how the contacts are aligned with the "D" key to the transmission. There's also a small metal tab on the side of the rotating piece that stops when it hits a metal tab on the fixed portion so it won't free-rotate...

Again, I put it back together just now and it tested OK, however the cap was lose - and when I took it off the contacts and springs where lost to the carpet gods.... :grin:

Good luck!
 

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You can test the sensor by turning the sensor switch with a screw driver when the ignition switch is on. As you turn the sensor, you should see the gear indicator change to show the different gear numbers. If this does not happen, your gear indicator is faulty.
 

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Discussion Starter #7
You can test the sensor by turning the sensor switch with a screw driver when the ignition switch is on. As you turn the sensor, you should see the gear indicator change to show the different gear numbers. If this does not happen, your gear indicator is faulty.
Thanks. I'll try this tonight.


Thank you to everyone to responding. Special thanks to Gino for the pictures, they are quite helpful.


-Kris
 

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2005 K1200LT
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Thanks for posting the pictures of the insides. I always wanted to see that but mine never failed.
 

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Thanks for posting the pictures of the insides. I always wanted to see that but mine never failed.
I saved some off in case they need to be referenced at a later date :)
 

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I pulled mine apart accidentally while getting ready to drop the trans. I put it back together but I'm not sure if I had those pins or not.

Have to pull it apart tonight.

Good timing on this thread
 

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I pulled mine apart accidentally while getting ready to drop the trans. I put it back together but I'm not sure if I had those pins or not.

Have to pull it apart tonight.

Good timing on this thread
Same here - I was not able to find the springs until AFTER I ordered the new one - Oh well.

I probably could have rebuilt it but knowing where it's located (and the one smashed spring) I didn't want to trust it...
 

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Mine reads wrong but the N still lights up so my centerstand will work. It doesn't bother me so I never replaced it.
 

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Looked at it tonight and all three of the small springs and their projectiles disappeared into the far corners of my garage. Guess I'll need to order a new one
 

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2005 K1200LT
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Note to self: If I ever disassemble the gear position sending unit - I will do it INSIDE a large plastic bag!!!
 

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2005 K1200LT
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It is right here, but you have to remove the cross tube to get access to it and the belcrank for the shifter.
 

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If you lie under the bike on centre stand with a good light you can get fingers from the side and bottom then both remove and replace the sensor without stripping anything. The trick is to get a small ziptie looped ready to pull on the end of needle nose pliers, slip the ziptie over the two spring clip ends and pull tight, locking them closed. Same for reinstalling then just pry off the ziptie after. It's a fiddle I used a finger in from the left side to move and press the sensor into place and wiggles the cable from beneath with my right had to rotate it when positioning. I've had mine off and cleaned it inside as I have no neutral light and no gear indicator on the dash.

Sadly on mine this has had no effect, I think my sidestand switch is faulty and causing it, the gear indicator was on and off last week and wiggling the sidestand put them back on. Its also not cutting the engine off in 1st with stand down.

Does anyone know if the sidestand causes the gear indicator on the dash to go off totally?
 

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2005 K1200LT
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Does anyone know if the sidestand causes the gear indicator on the dash to go off totally?
I see nothing in the wiring diagrams that suggest a connection. The gear indicator switch feeds directly to the dash controls and there is no connection from the side stand switch to the dash. But I suppose it is possible (hidden interconnection). I see you cleaned it but I think I would have tested it off the transmission before I put it back on just to make sure.

Nice technique for removing and installing it. I'll have to try that.
 
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Looked at it tonight and all three of the small springs and their projectiles disappeared into the far corners of my garage. Guess I'll need to order a new one
I have one, if you get stuck.
 

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I see nothing in the wiring diagrams that suggest a connection. The gear indicator switch feeds directly to the dash controls and there is no connection from the side stand switch to the dash. But I suppose it is possible (hidden interconnection). I see you cleaned it but I think I would have tested it off the transmission before I put it back on just to make sure.

Nice technique for removing and installing it. I'll have to try that.
The only reason I wondered was because the last 2 days it was working the neutral light and gear indicator went out occasionally when I turned it off. Flicked the side stand back and forth and they came back on so I thought maybe some kind of connection. Oddly my side stand switch currently allows the bike to run but does nothing if I put the stand down when in gear.

I also have no neutral light, oil temp light, engine temp light or batt light on ignition. The rev counter doesn't work nor does the fuel gauge engine temp gauge or gear indicator. All other dash lights indicators, lights, high beam etc work.

Couple of other tiny points, the battery light is supposed to get power from the alternator via a single wire on startup. It's not sending any on startup B+ pin is saying 0V. If I rev the bike the battery warning light suddenly gets power from the B+terminal and oddly... the battery starts charging (confirmed by volt meter 14.4v)

This is all off the back of a starter motor relay failure that jammed closed and the starter wouldn't stop spooling. Happened when I was riding and I lost the entire dashboard, it went dead. Replaced relay and starter (old starter worked but I figured why not) With new relay and starter the entire dash leapt back into life, then 3 days later … all the above.

I should add my bike is a 1998 K1200RS but they share pretty much everything with the LT, including the Clymer Manual lol.
 
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