On Saturday I made plans to go for a ride yesterday (Monday). However as one of the random little problems my new to me 2006 DL1000 front brake was not turning turning on the brake light. I did some quick tests and jumping the wire turned on the light showed it was the switch.
I didn't have enough time to order a switch so I took a crack at repairing it. I drilled out the three holes in the top of the switch a little to expose them as 2 separate pieces. Using a utility knife I pried the case halves apart exposing the inner workings, just a micro-switch designed for normally closed.
Examining the switch, it functioned correctly but the contact point were carbon-ed up and worn. I cleaned and sanded them down for good continuity. After some testing and a quick bit of tetrus to re assemble the switch (side note don't operating the switch too much outside the case or it will happily break down into tiny little bits), I had a functioning switch. I put the case back together and in the holes I drilled earlier I melted the the case parts together with a soldiering iron. I then gave a each hole a dab of epoxy for final sealing.
This way probably a waste of time as a new switch is $9.00 on amazon but I was in a rush and didn't have time for delivery, call it a successful little project.
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I didn't have enough time to order a switch so I took a crack at repairing it. I drilled out the three holes in the top of the switch a little to expose them as 2 separate pieces. Using a utility knife I pried the case halves apart exposing the inner workings, just a micro-switch designed for normally closed.
Examining the switch, it functioned correctly but the contact point were carbon-ed up and worn. I cleaned and sanded them down for good continuity. After some testing and a quick bit of tetrus to re assemble the switch (side note don't operating the switch too much outside the case or it will happily break down into tiny little bits), I had a functioning switch. I put the case back together and in the holes I drilled earlier I melted the the case parts together with a soldiering iron. I then gave a each hole a dab of epoxy for final sealing.
This way probably a waste of time as a new switch is $9.00 on amazon but I was in a rush and didn't have time for delivery, call it a successful little project.
