front brake switch repair
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Road Captain
Joined: Aug 2011
Posts: 693
Likes: 67
From: LI, NY
front brake switch repair
Brake light was on almost all the time. Pushing the front brake lever forward would often, but not always, turn the brake light off.
When I opened the switch housing the v-clip was missing, so I made one from scrap sheetmetal:
That did not fix the problem. Eventually I realized that the switch had to be moved in the opposite direction, away from the brake lever.
So I took the shim out and made a new one from a piece of bailing wire. A simple "U" with one long leg and the both ends hammered flat, inserted on the opposite side of where you see the v-clip. That moved the switch and squared it in the housing. Brake light works correctly now, just the right amount of free play before the light comes on. 
When I opened the switch housing the v-clip was missing, so I made one from scrap sheetmetal:
That did not fix the problem. Eventually I realized that the switch had to be moved in the opposite direction, away from the brake lever.
So I took the shim out and made a new one from a piece of bailing wire. A simple "U" with one long leg and the both ends hammered flat, inserted on the opposite side of where you see the v-clip. That moved the switch and squared it in the housing. Brake light works correctly now, just the right amount of free play before the light comes on.
Tourer
Joined: Dec 2013
Posts: 380
Likes: 8
From: Chicago, IL
Nice, I actually just had my switch break while I was putting on my new bars. I just found some spare hardware laying in the garage that fit between the button and lever and mine works great now too.
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