Rear brake light switch rebuild.
 

Recently I noticed, in a buddy's helmet cam video, that my brake light was staying on. At first I thought that maybe I was riding the rear brake, but it was staying on even when both my feet were on the ground. While doing my winter maintenance, I took a look at the rear brake switch, and sure enough it was sticking. A few taps would get it to snap back up into it housing, but it would stick nearly every time the brake pedal was depressed. I removed it, disassembled it, and found that dirt and water had gotten up into it and corroded the metal pin that slides up and down to make electrical contact.

Attachment 13083

depress the brass tabs in the square hole on either side of the switch housing, while pulling the whole works out. It's kind of tough.

Attachment 13084

Attachment 13085

Attachment 13086


A little cleaning and brushing with the wire wheel and it looks pretty good. Reassemble and good to go. I would like to find a rubber boot that seals this up, seems like a bad design to me ..

Before I found that the switch could be dis assembled I found this K & S Universal Brake Light Switch | ATV | Rocky Mountain ATV/MC on RMATV looks like it may work and be a cheap replacement option to the OEM switch.

Dan

Oddly enough I went on a trip this last summer and my brake light switch was sticking as well. When we were pulled over for a break, I started messing with it and I think mine was getting hung up on the little plastic protectors. I am thinking maybe I hit them with my boots? I don't know, after re-adjusting, they havent been sticking.

But in the future if this happens again, nice to know you can just take it apart and clean it.

Thanks for the how-to

I have one of these in my tool box, just havnt got around to install it yet. It replaces the bolt that hold the brake line to the master cylender.

https://www.denniskirk.com/dk/produc...ix/e120010.jpg

Hmm , I like that. I would never have to worry about dirt clogging it up. If my switch goes on the blink again, the hydraulic switch may be the route I go. Which thread pitch do we need for our bikes? (It looks like the 1.25mm P/N 21-0369) $22
Thanks, Dan

https://www.denniskirk.com/k-and-s/h...prd/210370.sku
PART NO. 21-0369 fits front and rear brake master cylinders on most Japanese street and off-road motorcycles; 10mm dia. x 1.25mm thread pitch
PART NO. 21-0370 fits most European motorcycles; 10mm dia. x 1.00mm thread pitch
Both feature 20 in. long wires with terminals
Single bleed

My brake light switch was sticking also.... im going to replace the stock switch with the pressure sensing switch.

Yeah; those OE switches are a real "rig." The one on the ZX9 was doing the same thing a few years ago. I replaced the switch spring with a 1/8" brass rod, so there is direct on/off every time with the center "slider" in the switch. The brake pedal is spring-loaded, so it works just fine. Hasn't malfunctioned or corroded since.....

That's another good idea! :D

....yeah, right up there with the re-bar..... ha!

Yes, P/N 21-0369 works on our bikes.

I installed it yesterday and it only took a few minutes to do.