Just got done wiring some new bars and putting everything back together. The only thing I don't seem to be able to get is the front brake lever to engage the brake light switch. The switch is working, when I pull the lever off and engage the switch with my finger so it's something I'm doing wrong with the install. I can't fit a 5/32" wedge in the lever, but I'm pretty close with a piece of doubled cardboard.
Any hints, clues, advice?

 

Did you put the cardboard in before taking them off of the old bars and keep it in until everything was back together on the new bars? If not, you need to replace the switch. If you did, you just have to be careful to get it n the right spot so the lever hits the switch. Kinda tricky and real easy to break it

 

Nope forgot to do it before hand, but there is nothing wrong with the switch. The boot isn't torn, it works as it should manually without the lever.

 

There may be nothing wrong with the switch itself but I'ld be willing to bet you chipped enough of the plastic to where it the lever doesn't engage it anymore.

Very common and really what else could it be

 

Make sure the little brass wedge is there or in the correct position. It wedges between the housing and switch to make sure the switch sticks out far enough.

 

Here's a picture of it.

 

I'm with rooti on this one, there is a good possibility you need to replace the switch.

 

For $20 it won't hurt anything to replace it. This thing has been fighting me too and nail. First the molex connectors didn't want to lock back together now this.

 

Got it fixed. I just mounted the brake without the switch housing so I was able to squeeze it enough to get the 5/32" wedge in the lever and then reassembled according to the manual and now it works.
Just got back from a 2 hour ride.

 

You know it's strange, I've rebuilt my master cylinder, replaced my levers and bars, I guess I've been lucky. Never put in a piece of card board and never broke a brake light switch.
Knock on wood.
But mine looks nothing like the one 2011FXDC shows.