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  #1  
Old 13th June 2019
mikam123 mikam123 is offline
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Default Brake light/hi beam question

Recently bought a 2001 883 custom, and currently, the gas tank is getting refined, so I figured it was time to change the front controls as the turn signal switch was messed up.

I got both the front controls switched and in the process of adding turn signals and a new brake/run light I found two issues. The first issue is the bike won't switch to hi beam on the front, is this because the bike is not all the way on? Or did I mess up the hand controls? The second issue is there doesn't seem to be any wire that turns on just the brake light, and not the run. I only found constant power on the wires and nothing that responds when the brake is engaged. Definitely new to wiring so there is a huge possibility that I just don't understand how the brake/run light works. I found wires that power the turn signals and all that seems to work well with the switches.
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Old 13th June 2019
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IXL2Relax IXL2Relax is offline
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Do you have a Factory Service Manual? Are you following the Schematics?

The Hi/Lo Switch has an incoming BLUE wire that is the power for the headlight - Outgoing from that switch is a WHITE wire (Hi) and a YELLOW wire (Lo) to the headlamp socket... double check the switch connections...

Did you follow the precaution in the manual about the front brake lever?

http://sportsterpedia.com/doku.php/t...h_-_front_rear

The Brake Light is operated by a RED/Yellow wire... The front and rear brake switches are in parallel - Pulling the front lever or pushing the rear lever will activate that RED/Yellow wire with power...

It is VERY LIKELY that you did not get the front brake switch properly aligned when you worked on the hand controls - Double check the placement & alignment - It is very common to get this wrong...

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Old 13th June 2019
mikam123 mikam123 is offline
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Quote:
Originally Posted by IXL2Relax View Post
Do you have a Factory Service Manual? Are you following the Schematics?

The Hi/Lo Switch has an incoming BLUE wire that is the power for the headlight - Outgoing from that switch is a WHITE wire (Hi) and a YELLOW wire (Lo) to the headlamp socket... double check the switch connections...

Did you follow the precaution in the manual about the front brake lever?

http://sportsterpedia.com/doku.php/t...h_-_front_rear

The Brake Light is operated by a RED/Yellow wire... The front and rear brake switches are in parallel - Pulling the front lever or pushing the rear lever will activate that RED/Yellow wire with power...

It is VERY LIKELY that you did not get the front brake switch properly aligned when you worked on the hand controls - Double check the placement & alignment - It is very common to get this wrong...

IXL _______ >>>> My Motorcyle Chronicles Are Here <<<<
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I do have the factory service manual. I followed the schematic closely for the left-hand controls, however, I didn't have it when I did the right and possibly xxxxed up the alignment for the brake controls. I will recheck that. I am also going to recheck my wiring for the left. The brake/run light that I got only as two wires, so I am assuming one is ground (black) and the other is power. is this incorrect?

Also, thank you for sharing sportspedia with me that is an awesome resource.
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Old 13th June 2019
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Quote:
Originally Posted by mikam123 View Post
The brake/run light that I got only as two wires, so I am assuming one is ground (black) and the other is power. is this incorrect?
If it's only two wires, it's likely that the light housing itself is intended to be grounded - then one wire is the 'always on' running light (taillight) and the other wire is used for the brake light (connected to the HD RED/Yellow wire)...

The bulb should be a dual element bulb (1157) and the low intensity element should be always on and the HI-intensity element is used for the brake light...

SP section on the taillight:
http://sportsterpedia.com/doku.php/t..._license_light


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Old 13th June 2019
mikam123 mikam123 is offline
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That was super helpful.

Just an update on the brake light solved. It is grounded to the housing, and when I hooked up the correct wires according to sportspedia (one to running, and one to brake) the brake light would only come on in acc and not ignition. I figured the ground might be bad, so I took apart the license plate bracket and sanded down all the bolt connections for better ground, and put it back together. The brake light switch is working now that I got the correct position and the light is correctly grounded.

One note, I did tear the rubber on the brake light switch as I didn't follow the correct procedure. But I glued on a little gasket on top and now it functions perfectly.

I have not checked the high beam issue yet.
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Old 13th June 2019
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Good for you and thank you for reporting the success so far.
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