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Bar swap question.

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Old May 11, 2012 | 10:44 PM
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Default Bar swap question.

I'm swapping my bars. Of course, I forgot to put something between the brake lever and the housing before removing it. Is it a sure-thing that I broke it now? If not, what's the test? See if the brake light is working when I'm done?

Also, I'm missing something with the wires. Do they get clamped inside the brake lever mount? It doesn't seem like there is any space, and it doesn't seem right to pinch them.
 
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Old May 11, 2012 | 10:56 PM
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It's not a guarantee it broke.

The only way to know for sure is to turn it on and see if the brake light is working or not. If it stays lit all the time, the plunger broke and is not turning off the brake lights. If they don't turn on at all then your brake switch is shot.

I'm on front brake switch #3, so it's a relatively common problem. The switches suck in general. You can find replacements (currently mine is a drag specialties one) on Ebay for around $15-$20 shipped. You just have to solder it in and put it in the housing. That can be a pain in the *** even for me. Last one took me about 35 minutes said and done...I considered that pretty good.
 
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Old May 11, 2012 | 10:57 PM
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Nice. Ok, so that's good news. About routing the wiring then...?
 
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Old May 11, 2012 | 11:00 PM
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Are the new bars dimpled like your old bars? The dimple is there for a passage for the wiring.
 
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Old May 11, 2012 | 11:09 PM
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Yeah, I thought about that. The new bars are dimpled and drilled, so I can squeeze the wire in there and it will pass. What makes me hesitate is that the hole is further out than the old bars, so if I use that space to squeeze the wires, it means mounting my throttle with some of it hanging off the end of the bar.

I have to be missing something here. BTW, no, we're not running the wires internally, I'm not up for all the cutting and splicing.
 
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Old May 11, 2012 | 11:14 PM
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You can move the controls out a little bit to make it work, it won't affect operation or reliability.
 
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Old May 11, 2012 | 11:17 PM
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Ok, we'll give it a go. Thanks gentlemen!
 
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Old May 11, 2012 | 11:38 PM
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Just throwing in my 2 cents. I change my bars frequently as I have a lot of different handlebars and get board. I never put the piece of cardboard between the lever and housing and have never had a problem, but I might have just jinxed myself...
 
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Old May 12, 2012 | 12:25 AM
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Seems like I'm one of the rare breed that actually enjoys wiring, even on a Harley..
 
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Old May 12, 2012 | 10:22 AM
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Originally Posted by fox4
Just throwing in my 2 cents. I change my bars frequently as I have a lot of different handlebars and get board. I never put the piece of cardboard between the lever and housing and have never had a problem, but I might have just jinxed myself...
Same here. I had removed the controls at least a dozen times before I even heard about the switch, and a dozen times after. Still no issue.

Originally Posted by Ironman 883
Seems like I'm one of the rare breed that actually enjoys wiring, even on a Harley..
Really? Wanna come over and redo mine?
 
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