KTM 390 Clutch Switch Pin Extender (repair)

This is a model of the top part of a KTM clutch switch with a counterbored and countersunk hole for a small self tapping screw.  These get broken if someone takes off the clutch lever without removing the switch first.  The particular bike this was made for is a 2018 KTM 390 RC.  The full length of the pin in the clutch lever is around 9mm to the rear face of the square that is below the pin.  In my case the length of the replacement top part needed to be 4mm.

The pin is about 3.3mm wide by 5mm long and has radiused ends.  The model is about 5.2mm long, this was to suite my printer slicer as with a 0.4mm nozzle it sliced slightly undersized at 5mm.

To fit it, I filed the broken end flat and sqaure, then I drilled a 1mm hole in the original dismantled switch pin and then screwed the parts together.  You may wish to open up the hole in the printed part.  The screw used had an OD of ~1.7mm and a total length of about 5mm.  I needed to lightly file the ends of the part as I was a little off-centre.  The screw was in the original part by about 2.5 turns.

The purpose of the switch is to allow the bike to be started in gear with the clutch pulled in (side stand up of course).  This is a typical situation if you stall a motorcycle.  It would be obvious to the bike user if this switch was broken because the only way to start the bike would be to be in neutral.

The original was printed with eSun PETG on a Prusa MK4 with input shaping and 0.20MM STRUCTURAL preset on PrusaSlicer. 

Image shows printed part on 1.5mm drill bit.