brake lever switch inop/spark plug boot replacement

[JCSkokos]

2 concerns as labeled in the title:
1st off, I was in an accident in late August and now that my shoulder doesn't hurt so much anymore I have had the itch to get back on. I replaced the bars(bikemaster and EMGO LTD bars are not the same unfortunately, and I can't remember where I got the EMGO ones), replaced the mirrors, got all the lights working again, and replaced the battery. Fires right up with no problems.

Now thanks to the insurance company I need to get the light inspection done. headlights, turn signal, and rear lights work normally and the rear pedal works right off, but the lever is intermittently not working as in it works if I squeeze the lever really hard, and it only does it sometimes. is there a quick fix for this that anyone knows of, maybe adjusting a connector inside?

Also, part of the damages came that the left outer plug cap/boot cracked. As I said, it still works and fires normally, but I would rather be safe about it. How do you replace one of these?

[tom203]

Glad you survived, and ain't gun shy! stuff happens .
Anyway, the spark plug boot just unscrews from plug wire- they are cheap, so replace it (cut off about 1/4 inch of wire to expose fresh copper) to avoid rain getting in there.
Try loosening the two screws on front brake switch and wiggle it around- you might get lucky and find the sweet spot. If not, put something under switch- hat ,paper bag- (to catch falling parts) and remove; might need cleaning.

[JCSkokos]

ok, figured it out. the brake switch seems a little loose so I 'padded' it with some plastic squares to keep contact. now it seems to work pretty consistently.
I also checked out the plug cap and I get how that works too. Thanks! one more: do you know a good place to get one, or all 4? Bike Bandit has them for about $20 each. even with the 10% discount and free shipping it seems a little steep.

[tom203]

That's probably why they call it bikebandit;try Z1 enterprises, probably get all four for less than $20 shipped.

[chuck hahn]

If you look at the brown curcuit board you will notice that one end has a little round raised bump molded into it..that end goes toward the end of the bars. As you squeeze the lever, the little U shaped contact slips off the ramp and slides across the two bars in the board to complete the curcuit to the lights, thus they come on. When you releease the lever, the U shaped contactor slides back up onto that spot and breaks contact with the wires.

You slightly loosesn the two screws on the cap and move the brown cucuit board and check the lever. Then snug down the screws and recheck..readjust till its working properly.

This is the same switch that the bikes with a clutch safety have and the process is the same there as well.

Last one i got was $9.99 plus shipping..Switch that is..

[JCSkokos]

damn! all 4 and new plugs for 21 even . I forgot about this site! This is where I got the EMGO LTD bars I liked so much, and over $10 cheaper than the bikemaster ones I got from BB.

[BassCliff]

Hi,

Front Brake Switch Repair
(by Mr. gravity tester)


Spark Plug Cap Replacement


Glad you're doing better. We should get together and ride soon. I'm sorry I've had no time to ride over to meet you. I work at Mt. SAC. We should do lunch sometime.


Thank you for your indulgence,

BassCliff

[JCSkokos]

There's the problem. the spring was missing!

I work right down the hill(north on grand ave) and a couple blocks over at the Kia dealer. I also am stressing a little bit about going to get 'er reregistered.