I have an 09 Road King Classic. I am changing out handlebars and adding the Chrome Switch housings. Everywhere is a warning to put a cardboard insert between the brake leveer and the brake lever bracket (see attached picture) However, the end of my brake lever isn't flat like the picture but comes to a point. I see no way to put anything in there but don't want to break the switch. I called a local dealer and the service guy wasn't sure what I was talking about. Any help would be appreciated.

 

I just changed the bars on my 09 Ultra. If you can't get a piece of cardboard in there, yours is different than mine. I just pulled the brake lever to create some space and inserted a fairly thin piece of cardboard. It took a couple of trys to get it thick enough to hold the lever, but thin enought to fit in the space.

 

I used a small wire tie, inserted the large end works great

 

I pulled the brake lever and used a couple of dimes and it worked fine.

 

Whats the reasoning for this? I just changed the levers on the fxr and didnt do this but had no problem with the switch.

 

jstride, if you look at the instructions for the HD chrome levers for '08 and up models, you'll see how to place the cardboard insert:

http://www.harley-davidson.com/en_US...ts/-J04278.pdf

The picture you posted is of the pre-'08 master cylinder/brake lever; the above link shows the '08 and newer m/c and brake lever.

Carl

 

Without that spacer in there holding the brake lever pulled, there is a very good chance of breaking the nipple off the brake light switch. then you've got to replace the brake light switch. That's a PIA job. Also depends on what year bike. HD changed the brake switch setup at some point in time, maybe mid 90's.

 

I didnt use anything on mine, I was just very very careful.

 

I put a 5/32 allen wrench in there and used some blue painters tape to keep it in place.

 

Grabbed small piece of cereal box from recycling to use on mine. If you pull brake lever - you don't see a gap where the switch button moves in/out??? Cardboard, or other slim protective item, is used to hold brake button & protect from snapping...