I was first alerted to a problem with the brakes on my bike when I started slowing down to make the left turn into my neighborhood and was suddenly assaulted by a blaring horn an obscenities from behind me. The guy driving the express delivery truck must have been pretty mad, because I could hear him clearly over the rumpling of my Screamin’ Eagle, and inside my half-face helmet. I made a quick check of my turn signals (I new I hadn’t forgotten to press the left turn button), and everything checked out.
A few minutes later, when I was back at home, I ran through a quick check:
- Did something fall off my bike and hit the other car? — No. Everything was where it should be.
- Did I have anything offensive written on my clothing?— Nothing that would elicit more than a disapproving glare from my grandmother (then again, she was very open minded and tolerant).
- Were my tail lights out? No. When I pressed the footbrake, it all lit up.
I check the brake again, using only the handbrake, and tail brake light stayed dark.
When I took off the break lever, the pressure-pin on the brake switch (which the brake releases when depressed) was stuck in its housing. No amount of coaxing could get it out.
So I headed down to Patriot Harley-Davidson in Fairfax, VA, and picked up a replacement switch for about $30.00 USD.
I was a bit nervous about replacing the switch myself: I can turn a wrench and change oil, but electrical troubleshooting is a bit beyond me. But the replacement switch came with good instructions with lots of drawings, so I decided to go for it.
Removing the brake lever was a simple task, since I’d already done it to check out the problem. Removing the electical switch housing and getting in to the bad switch proved challenging because my wiring is run inside the handlebars, and there really was no slack.
The brake switch was completely burnt out and had melted itself in a locked position. I had to gently muscle it out of the housing.
When I go the new switch in, I found that the release button (the part the brake pushes in and lets out to trigger the brake signal) was jamming. I loosed the screw holding the switch in to give it a little play, and jamming ceased to be an issue. I suspect this is what cause the earlier brake switch to burn out.
After some close wiring work (at least it was close to me), I got the new switch in and screwed and bolted everything back together.
When I tested the brakes using the hand lever, the brake light lit up instantly.
Hopefully the express delivery guy appreciates my effort and won’t drop my packages in the mud.