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10-13-2021, 09:05 AM | #1 |
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How to replace Voyager gear indicator switch?
Can you just remove the shifter and gear change cover to access the switch? According to the service manual, it looks like you have to tear half the left side case apart. Including water separator and generator cover. I've had the clutch slave and front pulley off, but can't remember how its laid out. FYI - My cruise won't set some of the time after 105,000 miles!
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Last edited by H8BUGZ; 10-13-2021 at 09:46 AM.
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10-13-2021, 05:34 PM | #2 |
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My cruise would not set and it was the switch for the foot brake that needed to be set. I don't have an answer for the gear indicator switch.
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10-13-2021, 07:00 PM | #3 |
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+1
My cruise would not set and it was the switch for the foot brake that needed to be set. I don't have an answer for the gear indicator switch. |
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10-14-2021, 02:13 AM | #4 |
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The shift sensor is mounted to a port on the side of the crankcase/tranny, and it reads a pin set into the gear change shift drum. So it requires some disassembly of the left side of the lower case but you should be able to do it without digging into the engine or tranny.
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10-14-2021, 10:49 AM | #6 |
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I have discovered the following in my disassembly.
Remove left floorboard/shifter assembly (for access only as my jack was in the way). Drain coolant at lower radiator hose, remove lower water pipe, clutch slave cylinder and pulley cover. Loosen belt and remove front pulley.
I ran out of time , but it looks like all that's left, is to remove wiring shield, unplug sensor harness and remove gear change cover. Fyi: pulley nut is 1.25" 12 point socket. I'll build a tool to hold pulley for tightening. Thanks for the inoperative switch, cruise issue tips. But I know it's the sensor, as the gear position is off as much as 3 gears sometimes. It always engages when the display is correct.
Last edited by H8BUGZ; 10-14-2021 at 02:16 PM.
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10-14-2021, 10:52 AM | #7 |
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[QUOTE=andyvh1959;726281]The shift sensor is mounted to a port on the side of the crankcase/tranny, and it reads a pin set into the gear change shift drum. So it requires some disassembly of the left side of the lower case but you should be able to do it without digging into the engine or tranny
Yes-the speed sensor is in a "port" on top of the case. But the gear position switch is pin operated and inside the gear change housing below the front pulley. Only parts required are a $10 gasket, silicone sealer for the wire harness grommet and a $124 gear indicator switch. Often the service manual is a little bit overkill, but this operation has you going to several manual sections and taking apart (WAY) more than needed. It's still quite involved, but you are not taking the engine side case off as indicated.
Last edited by H8BUGZ; 10-14-2021 at 02:11 PM.
Reason: CONCLUSION
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10-14-2021, 05:46 PM | #8 |
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A typical gear indicator switch is a five or six contact pod (depending if its a 5 or 6 speed bike), with a spring loaded pin set into the end of the shifter drum. So as the shifter drum moves when we operate the shifter, the shift drum rotates slightly one way or the other based on an up shift or down shift.
I read a lot comments that the indicator doesn't always show the right gear with every shift, but eventually does indicate properly. The shift drum cannot rotate until the next shift is chosen, so to me that means the indicator pin does not consistently extend to make ground onto the indicator switch. I say ground because the indicator switch has contacts which the indicator pin touches, then the circuit "grounds" through the metal in the tranny. If a shift is made and the indicator pin hangs up for a few seconds and doesn't touch the switch contact, it either does not indicate or perhaps indicates the last shift made. For 6th gear on the 1700, if the switch does not make contact the cruise will not engage as the cruise computer expects a signal for sixth gear engaged. I bet in most cases, the switch itself is not the issue, but more so the indicator pin not extending to touch the switch contacts. Perhaps riders who use synthetic oils have better more consistent shift indicator results? Maybe take the switch out, then access the indicator pin to see if something hangs it up? Maybe a better spring to push the indicator pin out more consistently?
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10-20-2021, 01:09 PM | #9 | |
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The indicator reads a specific impeadance for each gear and saw a video for another bike when he replaced the contacts that appeared worn and uneven. I suspect you could sand down flat again to provide good contact so it provides good contact and correct impedance. I believe cruise will not work if the bike cannot determine gear selection.
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02-07-2022, 06:31 PM | #10 | |
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Quote:
The shift indicator pin is cued to the shift drum so it moves the same as the shift drum, and the contacts on the shift switch are spaced radially to match the shift drum travel. The rotational travel of the shift drum is controlled by both shift tangs connected to the shift shaft. I assumed the shift switch is simply contact by position only.
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10-14-2021, 10:29 PM | #11 |
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Well, my pin and spring extend fully without binding and I use Amsoil synthetic oil. We will soon see.
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10-15-2021, 06:12 PM | #12 |
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The manual was originally written in 2009, and on 2009 models you do need to remove the water separator and alternator cover. For 2010 and later models they have a different coolant pipe that can be removed without all the extra work. The pipe is retrofittable to 2009 bikes so just cut the old one off and buy the later one. There has also been an update to the pin and spring, make sure you install the latest versions.
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10-20-2021, 03:50 PM | #13 | |
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Quote:
Sadly the pin is backordered with 100 - 110 day eta! (Per Partzilla) |
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11-03-2021, 06:21 AM | #14 |
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Thx for the info, mates!
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02-07-2022, 08:37 AM | #15 | |
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Quote:
The impedance is the issue. The tip of the pin on my skoot was a fine point. So my question is the oil additives becoming an issue with the fine contact point? The service manager where the work was done thought this might be a point to consider. With all the different oils and oil additives out there and some skoots having the problem, I would think this could be a possibility. I asked for the pin when the last one was replaced with the intention of taking it to a jewelry shop and have them apply a small ball of gold to the tip to improve the contact surface. Hasn't been done yet. I retired, tore the roof off of my house, broke a tendon in my shoulder, had back surgery. I've been so busy I don't know how I had time to work and raise 4 kids. To much fun is never enough.
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