I saw a post by Bluerose abouta stoplamp switch problem she had which enlightened me to new additional information I couldn't locate in my service manual nor see the part in my parts book. I am planning to swap out my brake & clutch levers for black powdercoated levers and am learning there is a V shaped wedge that goes between the switch and the housing.

Will I need to disassemble the right housing to change out the levers? Or is it as simple as removing the retaining ring, pulling the pivot pin and reassembling it with the new lever?If its in the service manual I didn't see it. I'm okay on the clutch side, but I don't want to damage the brake lamp switch on the right.

Any input would be appreciated.

Arvid

 

In the service manual it says to use a small pice of cardboard before installing the new lever. I did this and it worked good, I was warned buy a friend that did not do this and had to repace the switch because it broke. Place the cardboard up against the switch during placement of the lever then remove it.

 

The "V shaped wedge" that you're talking about is probably the spring that applies pressure to the brake light switch. When you disassemble the right side housing you can see it by looking at the back side of the switch. It just sits in there and could get lost if you're not careful.

Keep in mind that the clutch side housing on your '07 also has a clutch safety switch that looks just like the brake switch. It's possible to break that one too if you're not careful.

 

This is all you have to do to keep from breaking the brake light switch. Just pull the pin and swap the lever making sure not to damage anything in the housing when you reinstall it.

 

Also be sure you are using levers for '07 and newer. the clutch lever has an additional little bump on it that pushes against the clutch switch. the earlier models don't have this bump on the lever. if you use the wrong lever, you can't start it unless you are in neutral.

don't ask me how i found out.

 

Thanks for the insights. Especially that theres a simular switch on the clutch side as well.

Arvid

 

In my '04 HD SM, the brake lever wedge is covered in Sec. 2.10 (Front Brake Master Cylinder) with a picture shown at Figs. 2-41, 43 and 44.

What service manual do you have????

 

Okay, the front brake master cylinder in section 2 shows a better exploded parts view, and it even talks about the front stoplight switch p/n 00324a, but doesn't show the electrical stop switchin the exploded parts view.

In Bluerose's thread https://www.hdforums.com/m_3159732/tm.htm"Streeter" states ... Yes, there is a brass or copper V shaped wedge that fits between the switch and the housing (07). Also check and make sure the the small tip of the switch didn't get broken during your bar swap. Good luck

I'm not making reference to physicallyinserting a wedge of cardboard in between the lever and the bracket, I want to see the electrical switch and the copper V shim(Comfortably Numb refers to it). At the end of her thread Bluerose said the V wedge was still there, it just got squished, they widened it back out and put it back in, problem solved.

Unless theres something I'm missing completely, I want info on the electrical stop lamp switch, thats what I can't find. My service manual is 2007 Touring Models, p/n 99483-07. For the front stoplight switch in section 8, it says to see section 8.22 Handlebar switches, switch repair/replacement, it does not show the switch, it just cautions you not to damage it.

Arvid

 

Inserting the wedge as everyone is suggesting is to prevent damage to the rubber boot and the switch plunger. The wedge is supposed to be placed between the lever and the switch housing. In your case it isn't going to do any good because as soon as you pull the pin to replace the lever that little wedge is going to be on the floor. Just try pulling the pin and carefully removing and reinstalling the new lever. Can't find anything in the manual about replacing levers.

 

You won't see the copper V shim when changing out levers. It's inside the switch housing holding the brake light switch in place. What you will need to do is protect the tip of this switch and the rubber boot from getting broken/ripped when you do your thing. You won't need to remove any of the switch stuff on the bars to remove and install the new lever.
All you'll want to do is push the switch tip in and hold it there by taping a piece of cardboard in place between the end of the lever that activates it and the switch housing to keep it out of the way to avoid breaking it off.

CN