Me too!
My Fix for the Rear Brake Switch
Cool
Yesterday I read about the recall to replace the rear brake light switch on 2009-2011 Touring models. From what I understand the issue is heat degradation of the switch resulting in switch failure.
HDs fix is to replace the switch with a newer version. I assume this newer version is more heat tolerant than the original, but that still doesnt address the root cause of the problem. It wouldn't surprise me if these new switches start failing in the future, because from what knowledge I currently have on this issue, it doesn't seem to me that HD has addressed the root cause.
If heat is the issue, then minimizing that heat is the most appropriate corrective action in my opinion.
Following that train-of-thought, I went out to the garage and took a look at the location of the brake switch on my '11 Limited. The switch mounts to the frame directly adjacent to the exhaust header (and catalytic converter) with just over an inch between the two. Its quite obvious where the heat is coming from. Common sense tells me that protecting the switch from the heat source should solve the problem.
So thats what I did. This morning I spent just over an hour fabricating a heat shield to protect the switch. See attached pics. I still need to paint the heat shield I took these pictures prior to paint so it would be easier to distinguish the shield in the pictures. Once its painted black it will not look out-of-place at all.
Its a pretty simple way to get some additional insurance against experiencing a switch failure in the future with either the original switch or the newer version if youve had it replaced, or are going to have it replaced. Im undecided whether Im going to take my bike in for the newer switch or not. Im leaning towards just leaving it the way it is. My reasoning is that I removed the cat early on so my switch has not seen the extreme heat as those on a stock bike would, and the heat shield will provide for even less heat in the future.
HDs fix is to replace the switch with a newer version. I assume this newer version is more heat tolerant than the original, but that still doesnt address the root cause of the problem. It wouldn't surprise me if these new switches start failing in the future, because from what knowledge I currently have on this issue, it doesn't seem to me that HD has addressed the root cause.
If heat is the issue, then minimizing that heat is the most appropriate corrective action in my opinion.
Following that train-of-thought, I went out to the garage and took a look at the location of the brake switch on my '11 Limited. The switch mounts to the frame directly adjacent to the exhaust header (and catalytic converter) with just over an inch between the two. Its quite obvious where the heat is coming from. Common sense tells me that protecting the switch from the heat source should solve the problem.
So thats what I did. This morning I spent just over an hour fabricating a heat shield to protect the switch. See attached pics. I still need to paint the heat shield I took these pictures prior to paint so it would be easier to distinguish the shield in the pictures. Once its painted black it will not look out-of-place at all.
Its a pretty simple way to get some additional insurance against experiencing a switch failure in the future with either the original switch or the newer version if youve had it replaced, or are going to have it replaced. Im undecided whether Im going to take my bike in for the newer switch or not. Im leaning towards just leaving it the way it is. My reasoning is that I removed the cat early on so my switch has not seen the extreme heat as those on a stock bike would, and the heat shield will provide for even less heat in the future.
PS: Aluminum dissipates heat
Thread Starter
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Elite HDF Member
Joined: Nov 2010
Posts: 3,846
Likes: 173
From: Simi Valley, CA
What material was used for the heat shield? It was suggested by another forum member to use aluminum sheet goods, such as roof flashing, perhaps?
Does aluminum reflect heat or conduct heat? If it conducts heat, then would a remedy using this material actually move the heat closer to the switch? Would the aluminum shielding box in any heat in and around the switch? If the answer is 'yes', then it may be better to leave things be and have the recall work done.
Does aluminum reflect heat or conduct heat? If it conducts heat, then would a remedy using this material actually move the heat closer to the switch? Would the aluminum shielding box in any heat in and around the switch? If the answer is 'yes', then it may be better to leave things be and have the recall work done.
I used a scrap of sheet metal (steel). But aluminum sheet or galvanized steel (roof flashing) would also work. The roof flashing type material does not have the same thickness as what I used so it will not have the same rigidity and may require addtional mounting provisions to keep it in place.
All metallic sheet type materials will condct heat, but they will also dissipate, deflect, and redirect some of the heat energy. By placing a sheet metal barrier between the heat source and the affected item, regardless of the barriers conductive characteristics, less of the heat energy will reach the affected item provided the barrier is not in direct contact with either the heat source or the affected item.
As for "boxing in" or trapping heat behind the barrier, this may occur to a relatively minor extent, but the heat it does trap, if any, will be at a significantly lower temperature than the affected item would see without the barrier in place. The barrier is not sealed - it is open 360 degrees around its perimeter so any trapped heat is minimized.
I'm sure HD did its homework before issuing this recall and this new switch is an improvement over the original. But that said, if heat is the real problem, then minimizing that heat is an appropriate corrective action. Maybe not the only one, and not the one that HD chose, but it is nevertheless appropriate.
Installation of a heat shield similar to what I have done, along with the new switch from HD, is probably best insurance against a future failure.
I read another post in a different thread where the author's wiring to the brake switch fried and shorted out from the exhaust heat. The heat shield I've installed would also reduce the risk of that type of related failure.
Hope I've answered your questions.
Last edited by 2black1s; Oct 22, 2011 at 12:20 PM.
Outstanding HDF Member
Joined: Jun 2011
Posts: 2,023
Likes: 6
From: New Jersey
Good questions! I'll try to answer them the best I can.
I'm sure HD did its homework before issuing this recall and this new switch is an improvement over the original. But that said, if heat is the real problem, then minimizing that heat is an appropriate corrective action. Maybe not the only one, and not the one that HD chose, but it is nevertheless appropriate.
Installation of a heat shield similar to what I have done, along with the new switch from HD, is probably best insurance against a future failure.
Hope I've answered your questions.
I'm sure HD did its homework before issuing this recall and this new switch is an improvement over the original. But that said, if heat is the real problem, then minimizing that heat is an appropriate corrective action. Maybe not the only one, and not the one that HD chose, but it is nevertheless appropriate.
Installation of a heat shield similar to what I have done, along with the new switch from HD, is probably best insurance against a future failure.
Hope I've answered your questions.
I agree, too, that the appropriate resolution is to address the cause, not the symptoms.
Thread Starter
|
Elite HDF Member
Joined: Nov 2010
Posts: 3,846
Likes: 173
From: Simi Valley, CA
Thanks for the vote of confidence! But I don't think I'll be selling many of these. Making each piece by hand, I'd have to sell them for a price that very few people (me included) would be willing to pay.
If I had tooling to stamp these things out, I could make them at a cost of pennies per piece. But I'd have to sell hundreds or even thousands of them just to cover the cost of the tooling.
Then I'd have to do some comprehensive testing and data collection to validate its performance. At this point, my common sense and technical background tells me it will perform as intended, but I don't have any data to prove exactly how well it will perform.
It's really just an idea for any of you do-it-yourselfers, like me, out there.
Who knows, maybe HD already has something similar in the works for new models. And if they do, you can be certain they will make it available as an accessory for everyone with an earlier model to buy -probably at a cost higher than my hand made one LOL.
If I had tooling to stamp these things out, I could make them at a cost of pennies per piece. But I'd have to sell hundreds or even thousands of them just to cover the cost of the tooling.
Then I'd have to do some comprehensive testing and data collection to validate its performance. At this point, my common sense and technical background tells me it will perform as intended, but I don't have any data to prove exactly how well it will perform.
It's really just an idea for any of you do-it-yourselfers, like me, out there.
Who knows, maybe HD already has something similar in the works for new models. And if they do, you can be certain they will make it available as an accessory for everyone with an earlier model to buy -probably at a cost higher than my hand made one LOL.
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