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Taillight stuck on.

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Old May 21, 2024 | 08:20 AM
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Default Taillight stuck on.

So after my issue with blowing engine oil all over the place on Saturday I noticed on Sunday before getting out for my 1st ride of the season that my rear brake light was stuck in the illuminated position. I pulled the plug for the rear brake peddle and the light still did not go out. Proceeded to remove the front brake lever assembly so I could actuate the plunger manually but the light still would not go off. When reinstalling the brake lever ( too late to watch a YouTube video about breaking the tip off the plunger ) I did in fact break the little tip. Either way the light is still on. Is it possible I just have a faulty switch regardless of the broken tip now. I'm gonna spray some stuff in the switch as well just to see if that works but will have to replace the switch now anyway I guess. Not sure if I can glue that tip back on.

 
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Old May 21, 2024 | 08:33 AM
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What is the bike you are working on?

Sure, it's possible the switch was bad, but either way it needs to be replaced.

If you unplug the wires on the front switch (similar to how you did on the rear), does the brake light go out? On most years, the distance between the switch housing and the mastercylinder needs to be a certain distance apart so that the brake lever is close enough to keep the switch closed when the lever is released. So when putting things back together, check the manual for the space requirement.

If the light does go off when the wires are disconnected from borth switches, it's time to check the blub and wiring.

Paul
 
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Old May 21, 2024 | 02:31 PM
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More often than not, what is needed for this repair is the front brake master cylinder needs to be rebuilt. The spring inside the master cylinder gets weak over time which causes the lever to not seat all the way.
 
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Old May 21, 2024 | 02:53 PM
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Originally Posted by pgreer
What is the bike you are working on?

Sure, it's possible the switch was bad, but either way it needs to be replaced.

If you unplug the wires on the front switch (similar to how you did on the rear), does the brake light go out? On most years, the distance between the switch housing and the mastercylinder needs to be a certain distance apart so that the brake lever is close enough to keep the switch closed when the lever is released. So when putting things back together, check the manual for the space requirement.

If the light does go off when the wires are disconnected from borth switches, it's time to check the blub and wiring.

Paul
I have not disconnected the wires to the switch yet. Haven't had time. Will check it as soon as I can though.
 
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Old May 21, 2024 | 02:56 PM
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Originally Posted by Damnbiker
More often than not, what is needed for this repair is the front brake master cylinder needs to be rebuilt. The spring inside the master cylinder gets weak over time which causes the lever to not seat all the way.
I actually have a brand new chrome master in the closet from a year ago and I haven't gotten around to installing it for many reasons , mostly time to do it. I guess now that everything is apart it might be the perfect time to finally install it. New grips as well.
 
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Old May 21, 2024 | 03:42 PM
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Technically if I remove the brake lever it allows the plunger to the switch to extend all the way out which in turn should turn the tail light off if that's the problem correct? It wouldn't have anything to do with the master cylinder at that point if the master cylinder is not being used to engage the plunger. With the lever completely out of the equation I can use my little finger to push the plunger to the switch in and out yet the light still stays on. Perhaps I'm missing something.
 
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Old May 21, 2024 | 04:36 PM
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Replace the switch. Part # 71621-08
 
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Old May 21, 2024 | 04:38 PM
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It's a normally closed switch,
in other words, in is off out is on.
 
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Old May 21, 2024 | 08:16 PM
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Not sure what year or model your bike is. They used to have a wedge (V clip) in the front switch housing that held the brake switch in place. If that wedge broke the switch would move back in the housing and the brake light stayed on. The link is for a 2005 Heritage but might give you an idea about what I'm talking about. When you open the housing you're suppose to put a certain size wedge (3/16 I believe) between the brake lever and bracket so as not to put pressure on the switch which can break the V-clip. #9 in the diagram.

https://www.harley-davidson.com/us/e...OFTAIL_CLASSIC
 
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Old May 22, 2024 | 03:38 AM
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I called the dealer yesterday and they do have one switch in stock so they put it aside for me. I'm hoping I can just splice it in the the upper existing wire rather then trying to run it through the wire loom and down the bars. My bike is a 2006 Heritage Classic by the way.
 
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