brake light flicker - front brake lever play

[pswiatki]

I noticed my brake light flicker and was able to find the cause: front brake lever has just a bit too much free play and when I ride fast enough (on a highway, above 115-120 km/h - just above 70 mph) the wind pushes the lever enough for the microswitch to activate. Since there is no adjustment on the microswitch itself and it is mounted at a fixed position relative to the lever - how can this problem be addressed? Can I reduce the free play on the lever (so that the lever would not move enough for the switch to activate) or I risk that front brake could engage without my action on the lever? Perhaps it is just the matter of a worn switch that needs replacement? Has anyone experienced a similar problem?

 

[kiwi dave]

You could try mounting the switch further away from the lever. You might have to get a little creative with the mounting arrangement. Try leaving the screws out, and securely fasten it in the new further away position with some good tape. Worth a try.

Edit: If that's too hard, replace it.

 

[pswiatki]

Thanks for your suggestion. However, this is a safety-critical part. If the tape failed and the switch did not activate I could be rear-ended in a much different way than last time (when I had the opportunity to test my freshly installed engine guards from Hepco&Becker - but it wasn't my stoplight that caused it). So, I shall check how I can move the switch and still have it securely screwed in.
By the way: I taped over the microswitch on the other side (clutch) because it came apart somehow. The tape was really good (TESA tape, a kind of silver duct tape) but that was good only for a season, or so. I guess it deteriorated on the rain and high winds. Still [sort of] holds the switch together, but I will have to replace the switch, I think. Perhaps I should also try a new switch for the brake.

 

[kiwi dave]

You could cover your "safety-critical" issue by operating your rear brake in conjunction with the front, lightly if desired.

But your lack of an operating clutch switch is also a safety issue. Replace both would be a good starting point.

 

[Raven]

I would replace the clutch and brake switch. As the number of duct tape repairs begins to build, soon the bike becomes unreliable and dangerous. A few small repairs at a time is less overwhelming than a huge and expensive list all at once.

 

[Roblatt]

I had this issue on my B11. Fixed it by super-gluing a thin piece of plastic on the brake lever where it touches the micro switch.

Robert

 

[pswiatki]

I would replace the clutch and brake switch. As the number of duct tape repairs begins to build, soon the bike becomes unreliable and dangerous. A few small repairs at a time is less overwhelming than a huge and expensive list all at once.

True, I fully agree - with one remark: I think the clutch microswitch is less of a problem, as it can only become a pain when the clutch is actually disengaged, but the cluster / ECU doesn't get the confirmation from the switch. Then it will refuse to start the engine when the gearbox is in gear. Am I right? That is: unlike the front brake microswitch (which is a safety concern) the clutch microswitch is less critical. Hmm... although I can imagine the situation where the engine stalls and must be restarted quickly (no time to put in neutral, just to pull the clutch lever) - that would be an issue...
Anyhow, I shall order the switches and put them on the bike.

By the way: had the flicker on the stoplight mounted in the GIVI top case - it was always present (at low speed, too) - turned out to be a bad assembly inside one of their fancy touch-connectors at the case to mount plate touchpoint. At least that one was easy to address.

 

[Roose]

I noticed my brake light flicker and was able to find the cause: front brake lever has just a bit too much free play and when I ride fast enough (on a highway, above 115-120 km/h - just above 70 mph) the wind pushes the lever enough for the microswitch to activate. Since there is no adjustment on the microswitch itself and it is mounted at a fixed position relative to the lever - how can this problem be addressed? Can I reduce the free play on the lever (so that the lever would not move enough for the switch to activate) or I risk that front brake could engage without my action on the lever? Perhaps it is just the matter of a worn switch that needs replacement? Has anyone experienced a similar problem?

On my '14 Stelvio there is a plunger type switch that touches the brake lever. I can wiggle it and get the light to stay on. Everyone has told me replace the small microswitch that has the spade connectors, that appears to be a separate part? Maybe yours has a similar part/switch?

 

[pswiatki]

Well, I will take a picture of the switch and post it here. I guess the best option, for now, is to get a new switch and try if it helps.

 

[Tonym]

Had the exact same issue with brake light flickering. Rather than try and super glue a bit of plastic on the front brake lever as Robert did, a bit of 6mm fish tank hose works just as well (and I can't see it coming off in a hurry)