Front stoplight switch install
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Cruiser
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Front stoplight switch install
1991 Heritage removed old switch (wire broken at switch) and replaced with a new one. New switch isn't broken but cant see how the lever is supposed to make contact with switch. When plunger is away from switch light is on when pressed in it is off. Reinstalled throttle and master cylinder brakelight is still on. It appears that there is nothing to hold in the plunger in. Am I missing something? Feel like there should be something inside housing that the lever would move to release plunger and activate the light. and yes I do have an HD manual for my year and make.
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You may have damaged the new switch when installing it. They are fragile. That is why you have to place an insert (5/32') between the brake lever and the lever bracket when removing the assembly. There is also a wedge that goes between the stop light switch and switch housing. Check to see if that wedge is there.
You describe the switch action correctly. The brake lever holds the switch plunger in and allows it to extend when the lever is squeezed ( I couldn't think of a better word
).
You describe the switch action correctly. The brake lever holds the switch plunger in and allows it to extend when the lever is squeezed ( I couldn't think of a better word
).
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Cruiser
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Thanks for the reply!
Can't find any wedge looking piece. Where the switch enters/ mates with the housing there's nothing but a recess in the housing. The brake lever is smooth in that area ie nothing extends to engage switch. I've disassembled and reassemmbeled the damn thing so many times I'd hope that I would have figured something else out. Brake lever is shimmed by the way but that doesn't even get in the way or make contact with switch. This is driving me nuts. I rode the bike for several thousand miles without the new switch. Now it's 75 n sunny and I'm here rotating time between the garage and the computer. I'll try to figure something out. Anyone with some bright is welcome to chime in. Back to the garage.
Can't find any wedge looking piece. Where the switch enters/ mates with the housing there's nothing but a recess in the housing. The brake lever is smooth in that area ie nothing extends to engage switch. I've disassembled and reassemmbeled the damn thing so many times I'd hope that I would have figured something else out. Brake lever is shimmed by the way but that doesn't even get in the way or make contact with switch. This is driving me nuts. I rode the bike for several thousand miles without the new switch. Now it's 75 n sunny and I'm here rotating time between the garage and the computer. I'll try to figure something out. Anyone with some bright is welcome to chime in. Back to the garage.
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From: Norfolk, VA
You have to seat the front brake master cylinder assy right up against the switch housing to push the switch plunger in far enough to open the switch that feeds the brake lamp...I've been bitten by that a few times myself!!! 
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Cruiser
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I could be wrong but I don't think that I can get it any closer together. First time I put it back together it was out a little though. Anybody have a pic of this wedge piece that has been mentioned? Been lookin all over n nothin. I should mention that the new switch is identical to one that was replaced. The switch doesn't have a rubber boot. Just a plastic **** that sticks out. Back to garage.
Club Member
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From: Norfolk, VA
The **** that sticks out is the plunger that makes/breaks the switch connection. If you slowly pull on the front brake lever you may hear the switch "click" when that plunger moves out far enough..Sometimes the switch will not seat properly to allow the plunger to fit outside the switch housing...Like you said, take another look!
Last edited by SportsterBob; Mar 16, 2012 at 06:22 PM.
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From: NJ
2 most key things.
1 the wedge! got to have the wedge properly installed. That's what keeps the switch in the housing pushed forward to stay put and protrude the micro switch out the port hole.
2) having the switch housing and c lamp properly pushed tight together.
1 the wedge! got to have the wedge properly installed. That's what keeps the switch in the housing pushed forward to stay put and protrude the micro switch out the port hole.
2) having the switch housing and c lamp properly pushed tight together.
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The switch plunger MUST have the rubber boot. I once tore the end off the rubber boot and that caused the brake light to stay on. The thickness of the rubber boot makes the difference. Put some layers of duct tape on there temporarily and I bet you will have a working brake light.
The wedge is a V shaped piece of metal that slips between the switch and housing. It may have dropped on your garage floor.
The wedge is a V shaped piece of metal that slips between the switch and housing. It may have dropped on your garage floor.
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Cruiser
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Thanks for any and all input on this. Switch fits very firmly in the housing. There was no "wedge" when the housing was opened. Looked everywhere and I'll keep looking. Previous owner may have lost it though. Switch was new in package and came without a rubber boot. I looked at some posts but that area of the housing looks a little different from the others. The bike is over 20 years old so it's gonna have it's quirks I guess. Even if I can't find any missing parts I think that I've figured a way to make it work. While I'm waiting for devine inspiration I'm making a piece of spring steel that will actuate the switch maybe not as designed but it will get me on the road in the meantime. If it works or I find anything I'll post it up.
In case anyone was wondering the piece I'm gonna try to make will slip between the brake lever and the plunger that goes into the front brake master cylinder. When the brake lever is not engaged it will hold the switch in. When the brake lever is engaged it will move with the plunger thereby firing off the brake light. God I hope this doesn't get all Beverly Hillbilly on me!
Thanks again for all your responses!
In case anyone was wondering the piece I'm gonna try to make will slip between the brake lever and the plunger that goes into the front brake master cylinder. When the brake lever is not engaged it will hold the switch in. When the brake lever is engaged it will move with the plunger thereby firing off the brake light. God I hope this doesn't get all Beverly Hillbilly on me!
Thanks again for all your responses!
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Cruiser
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Problem solved. Figured out the problem. I confirmed with a HD tech that there is no rubber boot for the switch on my bike. He also showed me what was missing. Page 2-39 in the manual shows part 20 (pushrod and switch). Which isn't the switch really just a pushrod with an elongated or oval shaped washer attached in the middle. This "washer" is what actuates the actual switch in the other housing. I removed the pushrod and brake lever from the master cylinder and sure enough there it was but it was missing the elongated portion that would have extended into the cavity in the housing. Dealer said that they don't carry that part so I went ahead and made a piece that does the same job. First one I made didn't hold up too well. Half of it went flying across the garage never to be found again. Next one did the trick. Everything is reassembled. No binding in the lever and the brakelight is on and off when it's supposed to be. I would have taken pics to post up but wifey has the camera. Hope this may help someone in the future. Oh when doing any work that involves removing your brake lever start by putting your bike where it will live until you are done with the job. If you don't you might be glad that you have engine guards. Yes I finally dumped it. At least it was inside and no one saw me do it