How do I over ride the system so I can start my 03 620ie when it is in gear?
Thanks
Pull in the clutch.
Note that it won't start with the kickstand down either. Though that can be easily disabled.
If pulling the clutch doesn't do it, then there's something wrong with the wiring or the switch.
With the kick stand up and the clutch in I can't start the bike in any gear. I have to put it in neutral before it will start.
I also found out when the engine is on and I put the kick stand stand down when it is in 1st gear, the engine will die.
the later is normal. get cose to your clutch with the engine off, pull the lever in, do you hear a click? if not, look closer, theres a microswith there, your lever needs to hit it, might just need adjustment, or the siwtch is not there for some reason.
It's the switch at the clutch lever. My bike did the exact same thing. Sucked the first time I killed it at a light (and motivated me to stop doing THAT).
Check for tight wire connections at the clutch lever. I ended up paying the dealer $150 to figure this one out, because they told me I did it to the bike so it wasn't warranty.
Where about's is the switch? I do have CRG clutch levers on, not sure if that is causing the problem.
I looked for a switch and some wires around the clutch lever but did not see any.
There is a little adapter that you need with the CRG levers so it will engage the switch. Who ever installed them probably didn't have it so they removed the switch. You can find the wires in the harness that runs up to the controls on the left hand side and just jump them. Be warned that the bike will start in gear with the clutch engaged.
I don't see any loose wires in the handlebars, I do see two wires coming out a harness next to the head light. They are black and purple and don't go anywhere.
Looking in my Haynes manual I see on the 2004 620 it has a clutch switch on the wiring diagram. But on the 2003 diagram it does not. Does that mean the 2003 models don't have that micro-switch?
Consider it a safety feature. At least you know it wont lurch out from under you. Personally for me I always start the bike in N, kick it in gear then take off. But thanks to you, now I know what that micro switch on my 620 does. I had bought these levers that did not engage that switch, since I didn't know at the time what it did, I thought it important enough to return the levers...