When the brake lever is in resting position, the lever is not making contact with the brake switch. Therefore, the brake lights are always on. If I push the brake lever forward, it makes contact with the switch and brake lights turn off. So, the switch is working properly. There really isn;t any adjustments to be made.

A couple of winters ago, I replaced the stock bars with Chubby 504s with internal wiring; and brake line with Magnum Chromite upper/lower halves, bleeding the brake line after install.

I'm wondering if the problem is with the hydraulics. Is it possible that the master cylinder piston is not fully extended because lack of back pressure caused by either air in line or possibly caliper pistons not fully releasing???

My 07' Deluxe has 16K on the front brakes. I'll probably pull the caliper and check the pistons anyways.

any thoughts is appreciated... this problem has been driving my crazy!!!

 

When you changed out the bars, did you put the spacer between the lever and housing before removing the controls? The switch spring can be damaged if you didn't.

 

yes. piece of cardboard. When I looked at a bike at the bike shop, the lever is snug and tight. Mine has a little play and needs to push against the switch. The only thing I can think of is the master cylinder piston isn;t pushing far enough against the lever...

baffled....

 

my bet is the brass wedge behind the switch has moved, as is letting the switch fall too far inside the switch housing. steve

 

Yep good point snip0721. Worth checking out ronyd.

 

That'll do it every time.

Other than that, it would have to be a broken plunger but seeing as it was working for some time that doesn't seem very likely.