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  #1  
Old 19th June 2020
hondo hondo is offline
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Default Front Brake Master Cylinder Brake Light Switch

Is there any adjustment on the front brake light switch? The search function is down right now.

I have to ride with light pressure to the inside of the front brake lever to keep the brake lights off. In other words with normal vibration causing the front brake lever to jiggle turns the brake lights on and off.
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Old 19th June 2020
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Default

No adjustment there.

Is your plunger spring weak? Sticky?

Have you changed the levers?

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Old 19th June 2020
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You broke the plunger on the switch
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Old 20th June 2020
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It sounds like if you hold the lever forward the light goes out just fine right?

The lever should go all the way forward from the pressure of the spring behind the piston inside the MC. If it does not, you need to rebuild the MC. They get to where the lever doesn't return well from gum buildup inside the MC around the piston, (looks like green slime). Clean it out, replace the piston and the cups (you buy it as a packaged kit), it's cheap, flush out all the old fluid as you bleed, and when done the thing will act like new. The switch is a N-C switch (normally closed), so you know that the spring in the switch is good by the fact that it does push the switch out to make its normal contact. When you release the lever that pushes the switch in (when it is working right), plunger IN is the open position of the switch.

Note: examine that plunger, if you broke it off like Rocketman suspects you would have similar symptom, except I don't think pushing the lever forward would help unless there is a little piece of the plunger still there. They do break easy when you remove the lever unless you remember to put a small wedge in there to hold the lever back for removal.

Examine it closely and you will see what we are saying.
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Old 20th June 2020
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Quote:
Originally Posted by rocketmangb View Post
You broke the plunger on the switch
Quote:
Originally Posted by wedge View Post
They do break easy when you remove the lever unless you remember to put a small wedge in there to hold the lever back for removal.

Examine it closely and you will see what we are saying.
Yep! 'experience expert' here. Ruined one, same symptoms.
Next handlebar change I used a coin to get around 3 to 5 mm slack and a piece of tape to hold it in place.
(...I think it's even in the FSM......)
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Old 20th June 2020
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Small screw can help, take the place of the broken button.
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Old 20th June 2020
hondo hondo is offline
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Default

Never removed the front brake lever. Lever has 1/8" or so of slack. Removing the slack turns off the brake lights.

Thanks guys, I've got a rebuild kit sitting on the shelf. Perfect time to upgrade to dual S/S wrapped brake lines off the M/C.
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Old 21st June 2020
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Default

Quote:
Originally Posted by hondo View Post
Never removed the front brake lever. Lever has 1/8" or so of slack. Removing the slack turns off the brake lights.

Thanks guys, I've got a rebuild kit sitting on the shelf. Perfect time to upgrade to dual S/S wrapped brake lines off the M/C.
Yeah, you will be glad you did this, the MC is definitely gummed up.
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