Front Brake Light Switch Fix
I just purchased a 2000 Roadstar this weekend. 25K miles and in excellent shape. I noticed the brake light was not coming on when pulling only the front brake lever. Worked fine with the rear brake pedal. I pulled the front brake light switch and was measuring over 5MOhms in the normally closed (without button pushed) position. I looked online and found a replacement in the UK for $9.95+shipping but decided to see if I could somehow fix it. Here is what I did.
1. Removed the switch by removing a single screw.
2. Switch has a plastic body with two sides that are pressed together. I carefully scored the seem with a razor blade just to get a slit for a thin regular screwdriver head.
3. I used a small thin regular screwdriver head and carefully hammered it in, wedging it between the two plastic body sides. I continued to work my way around the switch body until I was able to pop the top off of the switch.
4. BE CARFUL not to lose the small plastic button of the switch.
5. Once you get it apart you will see where there is carbon build-up on the contacts.
6. Place a small amount of electrical grease on the contacts and use a wire brush to remove the carbon build up.
7. Place a small amount of electrical grease on the outside connectors and use a wire brush to remove any carbon build up.
8. Use an Ohm meter to check the continuity without the pushbutton depressed. You should get a short (close to 0 Ohms).
9. Use an Ohm meter to check the continuity with the push button depressed. You should now get an open (100MOhms or higher).
10. Ensure the pushbutton is placed properly and carefully press the body back together.
11. Re-install the switch on the front brake lever arm and test.
Should work as good as new.