Hi guys, I did a dumb thing the other day--- I removed the front brake/control switch off the bars and forgot to put the 5/32 piece of cardboard between the brake lever and the switch housing before removing. Bike is a '96 Softail, the brake/switch unit is Custom Chrome.

Didn't even think about it until I got it back together and started the bike and realized the brake light is on continuously.

Is it possible to reset the switch or is it now permanently damaged?

Any ideas on how to fix this are much appreciated.


Thanks and Regards,
V2Evo96

 

They are a little tricky. You need to be sure the housing for the master cylinder (brake lever) is snug against the switch housing and lined up correctly. I've had them apart a lot over time and seems like half the times I have to re-do that for the very same reason...

 

thanks t150,

Sounds like I need to pull the switch/lever combo off, pull back and aligh the switch plunger and insert the 'cardboard spacer' then re-assemble watching for proper alignment, etc.

Sounds like a fiddly job that I've never had to do but should be fine.

Thanks for your speedy response!
Best,
V2

 

All fixed-- what happened originally is that by not putting the 5/32" spacers between the brake lever and the housing, the tab on the brake lever that engages the push switch was pushing sideways on the switch not allowing the lever tab to engage at the end of the switch.

Fortunately, the rubber boot was OK although I can see where the lever tab was pushing sideways on it.
The fix was to re-set the switch button to its original centralized position, then reset the master cylinder switch housing onto the handlebar with the 5/32" spacers in position. (3 heavy duty tie wrap pieces worked for this)

Re-centering the switch was key to getting it to work again-- just good luck on my part the switch wasn't damaged....

All Good, thanks again t150.
V2Evo96