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Sportster Motorcycle Tires, Wheels, and Brakes Discuss issues with Sportster motorcycle tires, wheels and brakes.

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  #11  
Old 14th August 2020
canoli's Avatar
canoli canoli is offline
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Join Date: May 2017
Location: Washington Heights NYC
Posts: 126
Sportster/Buell Model: xlh1200
Sportster/Buell Year: 1992
Reputation: 98993
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Default

Ah nice, wires outside. I just changed my bars last wknd and ran the wiring inside. Oh well it shouldn't be too hard making the electrical connection. I need to find the thread pitch of the master cylinder banjo bolt I guess.

EDIT: banjo fitting size/TPI on the m/c is 7/16-24.

Thanks for sharing what you did - a banjo switch sounds like a great fix.

Last edited by canoli; 15th August 2020 at 17:46..
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  #12  
Old 23rd August 2020
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Default Finally fixed

'92 XLH 1200
My brake light is now working correctly. Thank you to PetesPonies for the suggestion (and the pic) of a banjo switch, which I installed without much trouble this morning. It works perfectly. Installing a banjo pressure switch is such an easy, smart fix.

I never figured out what the problem was but I understand (after lots of YT) it's a common occurrence on Harley brake levers/switches from that era. Later they went to a better system where the tab that activates the plunger on the brake switch is part of the brake lever. But these older ones with the master cylinder pushrod do suck indeed and I'm glad to be rid of it!

Thanks again!
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