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so after hearing some advice about the stop light switch plunger that won’t make contact with the brake lever I did my own digging. I had followed advice on gluing a small washer to the plunger tip and after a couple days it would fall out. So I tore the switch housing apart and low and behold the whole switch had slid back 1/16”. All I had to do to fix this annoying problem was use a flat screwdriver to pry the switch back to its original location and drop two washers between the switch and housing and drop a glob of silicone glue to keep it all in place. Total cost of repair $5. I had to replace the blown out bulb from it staying on.I hope this helps release the frustration of other riders. This seems to be a systemic problem with late model Harley’s (about 2005 and up).
The easiest thing to do is follow repair manual instructions and not damage the switch in the first place.
In actuality the procedure about that specific switch and proper R&R of the grip is or can be found on this forum in about 100 topics.
Cost of repair for doing it right the first time = $0
There is no annoying problem, screwdrivers or washers involved.
The "tool" needed is a piece of folded cardboard.
I still don't completely understand how you can break that switch so easily if you are paying attention to what you are doing and don't go all ham-fisted and force the lever back on...
...but then I watched as my son did it on his '04 LR when he was replacing his levers and he was being careful, so I guess it ain't that difficult and that's why it happens so much.
The lever releases the plunger to turn on the light so the trick I use is to take off and install the lever with it fully pulled back which keeps it completely off of the switch plunger. Gently line up the pin hole and drop the pin in...the switch plunger is not touched until I release the lever after the pin is in place. This has worked every time so far...
Last edited by skinman13; Sep 30, 2017 at 09:07 AM.
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