Gear indicator not showing the right gear

[24racefan]

When going up through the gears 1-2 is ok 3rd will show for 3 and 4th then 4th will show for 5 and OD. Sometimes after you ride for a while to will show the right gear. Anyway to fix this. Also will not let you set cruz when showing 4 when you are in OD. Take any help I can get. Thanks.

[Gypsy Dragon]

Known issue. If your bike is under warranty, you can take it in to get fixed, but the sensor is inside the transmission, which means they have to pull the motor, and tear it apart, so the bike could be in the shop for a bit.

[redjay]

Originally Posted by 24racefan

When going up through the gears 1-2 is ok 3rd will show for 3 and 4th then 4th will show for 5 and OD. Sometimes after you ride for a while to will show the right gear. Anyway to fix this. Also will not let you set cruz when showing 4 when you are in OD. Take any help I can get. Thanks.

Unfortunately you have to live with it.
Not a big inconvenience.

[gv550]

Originally Posted by 24racefan

When going up through the gears 1-2 is ok 3rd will show for 3 and 4th then 4th will show for 5 and OD. Sometimes after you ride for a while to will show the right gear. Anyway to fix this. Also will not let you set cruz when showing 4 when you are in OD. Take any help I can get. Thanks.

Common issue. Most of us just live with it, sometimes tapping the shifter will make it display OD and you're good to go.
It's caused by a faulty switch, there hasn't been any updates but the later ones seem better. I've replaced my switch a couple times, not a big job if your bike is 2010 or newer but the switch is expensive. Drain the coolant and remove the front pulley and external shifter cover and the switch is inside the cover. On 2009 models the alternator cover has to come off too which is extra work.

[Snake Ranch]

Originally Posted by Gypsy Dragon

Known issue. If your bike is under warranty, you can take it in to get fixed, but the sensor is inside the transmission, which means they have to pull the motor, and tear it apart, so the bike could be in the shop for a bit.

I have a 2011 Vaquero. Had the same problem. The shop doesn't have to pull the engine and disassemble it.

I didn't stand and watch them replace the switch, but the tech did it by draining the coolant and pulling the left side apart to access the switch.

SO he said. I know for a fact the engine was not pulled.

And the problem was corrected. There is an updated switch.

So unless there is a workaround, the switch is not that deep into the engine.

A person might look at this web-site. It is under the left engine cover, if I have my intel correct.

http://www.kawasakipartspitstop.com/...h-comp-neutral

$117.00 plus tax and shipping.

[DragonLady58]

What SR said! Look at the parts schmatics, see its location, and also check its price. Kinda expensive. Just make sure they get the belt to the correct tension, thats almost as big a beef as having to put in a newer updated switch....some techs just can't seem to get it right....

[Kopperhed]

Originally Posted by Snake Ranch

I have a 2011 Vaquero. Had the same problem. The shop doesn't have to pull the engine and disassemble it.

I didn't stand and watch them replace the switch, but the tech did it by draining the coolant and pulling the left side apart to access the switch.

SO he said. I know for a fact the engine was not pulled.

And the problem was corrected. There is an updated switch.

So unless there is a workaround, the switch is not that deep into the engine.

A person might look at this web-site. It is under the left engine cover, if I have my intel correct.

http://www.kawasakipartspitstop.com/...h-comp-neutral

$117.00 plus tax and shipping.

$91 at Partzilla

[gv550]

There is no updated switch, same part number today as in 2009. Later production switches work better and seem to last longer so it appears the quality has improved over the years. Every switch that I've replaced has been broken, a crack across the circuit board and sometimes at the mounting holes too.

[Scootergptx]

Bought mine used, and I noticed it would do this from time to time. RPM's tell me more than that does anyway. Funniest thing was the OD symbol. When I don't look through the reading part of my glasses, I swear it looks like this, ∞.

[Gypsy Dragon]

Originally Posted by Snake Ranch

I have a 2011 Vaquero. Had the same problem. The shop doesn't have to pull the engine and disassemble it.

I didn't stand and watch them replace the switch, but the tech did it by draining the coolant and pulling the left side apart to access the switch.

SO he said. I know for a fact the engine was not pulled.

And the problem was corrected. There is an updated switch.

So unless there is a workaround, the switch is not that deep into the engine.

A person might look at this web-site. It is under the left engine cover, if I have my intel correct.

http://www.kawasakipartspitstop.com/...h-comp-neutral

$117.00 plus tax and shipping.

My mistake, I haven't had it done, but was lead to believe the switch was deep in the trans. Thanks for the correct information. I will stop spreading lies.

[Snake Ranch]

Originally Posted by Gypsy Dragon

My mistake, I haven't had it done, but was lead to believe the switch was deep in the trans. Thanks for the correct information. I will stop spreading lies.

Don't feel like the Lone Ranger. I was told the same thing. I didn't find out till I went to get the problem corrected. I thought they would have my skoot down for a longer time.

I was told by the tech that the switch was changed from a contact type switch to a Hall Effect switch.

The part number may not have changed but I was told the way the switch was made has been changed.

I didn't see the old or new switch, but Caterpillar went through the same learning curve with one of their transmission switches. Same type of problem. I can't tell you how many of those things I changed.

[gv550]

The switch hasn't changed, always was and still is a contact type. A spring-loaded plunger on the end of the shift drum lines up with various buttons on the switch and each button is potted with a different resistor on the circuit board. The ECU reads the resistance and displays the appropriate gear, if it's working properly. The circuit board cracks, and the resistance goes out of range so the ECU doesn't know what to display.
The service manual gives the resistance spec for each gear, if out of spec that justifies a replacement switch under warranty.

[24racefan]

Thanks to all. For now I will just live with it. Only time it's a problem is when I want to use cruz and it says it is in 4th. It won't work. Thanks again for the help.

[JD Hog]

This is from the Service Manual

You should be able to use it from 3rd through 6th gear and between 30 to 85 mph.



Cruise Control Set Indicator Light (LED) Inspection
○The cruise control set indicator light (LED) [A] actually
goes on at the cruise control condition.
Cruise Control Main Conditions:
The cruise control ON/OFF button is ON position. The vehicle speed is 48 ~ 137 km/h (30 ~ 85 mph). The gear position is 3rd, 4th, 5th or OD (6th).
Any service code does not appear.
The cruise control switch (SET/) turned to ON.
If the cruise control set indicator light (LED) does not go on at the cruise control condition, check the following items. Right Handlebar Switch Housing (see Switch Inspection) Speed Sensor (see Speed Sensor Inspection)
Gear Position Switch (see Gear Position Switch Inspec-
tion)
Cruise Control System Switches (see Cruise System
Switch Inspection)
If the above items are good, replace the meter base and/or ECU.