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So as I'm wrapping up repairs to my wife's 20' XL883N I noticed that the brake lights were "stuck" on. Tracked it down to the front lever brake switch. Realigning the lever with the switch housing doesn't fix the issue and the switch itself appears to be working fine, the issue looks like the switch itself is not tall enough to properly come in contact with the brake lever. All that is there on the switch side is the off white plastic switch itself. I could have sworn there was something else on top of that? A black rubber boot maybe? Also, when the lever is fully released it is coming in contact with the lever housing, metal to metal and I thought that there is supposed to be a gap there.
I'm wondering if I lost a piece when I tore down that switch housing? The parts diagram is not really detailed for that specific switch so I can't tell. Can someone verify what their late-model Iron brake switch looks like and what kind of gap they have at the flat end of the lever?
Ok, good chance the brake reservoir is the culprit, Brake fluid gets nasty and gums up not allowing the plunger to fully extend.
Most times flushing it clean it up, then again just as many times needs replaced.
Youtube has the walk thrus, did you remember the lil piece of paper wedge when reinstalling is another thought.
There should be a little plastic nub on the end of the switch.
If you’re messing around up there and you’re not careful when you put it all back together you can break that nub off.
When the nub is broken off when the brake lever is released it won’t push in the switch which turns off the lights.
I believe the pic below is what’s on a ‘20 Sportster.
If it's not the switch replace the master cylinder.
If that front brake locks up on you you'll get hurt!!
Been there done that.
Flush the whole system too.
Put a small screw in it build it up with epoxy or replace it
Good tip; my 09 Heritage uses a different switch but uses the same principle.
When I broke off my "nub" I cut off the head of a 20d nail and then glued it onto the switch which was enough to shut off the lights.
I then order a new switch but didn't install it for 2 years until one day I just to decided to swap the switches.
The head of the nail never did fall off but I didn't want to press my luck too much..
Thanks for all the suggestions. So here's my deal. The master is brand new just came out of the box. The "nub" or whatever you want to call it is there, it's white plastic and I can see it moving with the lever, just not enough. The first reply got me thinking that I hadn't even filled the master yet, thinking that it would have nothing to do with the switch. Well, I filled it and now I have another issue, it won't build pressure. I've been bleeding it and bleeding it and it's pushing fluid and it looks like there's no air in the system now, but still nothing at the lever, it goes straight to the grip. So I'm wondering since the master is new, does it need to be bled? do I have a bunch of air trapped up there? Or I guess it could be defective too...thoughts?
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Front Brake Switch
