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GSX-R 750 Pictures of how I fixed the corroded brake light switch on the front brake lever on my 1985 1986 1987 Suzuki GSX-R750 motorcycle.


But first, lets pay some bills:
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  1. Brake lights. No brake lights when I squeeze the front brake lever. This is a problem. I'll tear the hand brake lever apart and see what's up.


  2. Under the front brake lever assembly there is some wiring coming out. The brakes are hydraulic, so this must be the brake light switch. Two (corroded) screws under the switch hold on this little cover.
    Brake Switch Cover


  3. Under that cover I find this pile of fuzzy aluminum corrosion and crud.
    Brake switch corrosion


  4. Here's what it looks like under the switch assembly. Rusty corroded mess.
    Brake switch corrosion


  5. That bolt that holds on the brake lever is so stuck it took a hammer to get it loose.
    Hammer


  6. Here are the parts out of the brake light switch. Screws, cover, nut, bolt, brake lever.
    Brake switch parts


  7. And here is this little switch contact that fell onto the floor and I am darn lucky I found all the parts. Copper contact, spring, plastic contact housing. Plus the bolt came out nice after some wire brushing.
    Brake switch parts


  8. Here is the brake lever and hydraulic brake plunger housing filled with corrosion. It's a wonder I could squeeze the lever. Must be my superhuman strength.
    Brake lever housing


  9. I Cleaned everything the best that I could using a small wire brush. I wish I had a smaller brush but I think I got the job done ok without harming the rubber seal around the hydraulic brake plunger.
    Brake lever corrosion cleaned


  10. I greased everything up with some white lithium grease. This is supposed to cling there for years and not rub off or wipe out.
    Grease


  11. Here is that little contact assembly put back together. All that time playing with legos finally pays off.
    legos


  12. Here is the other half of the brake light switch contacts cleaned. I put this on with the wires facing the back of the motorcycle.
    Install switch


  13. Then I put the little lego contact jobbie into the slot inside the lever housing with the copper facing down so it will touch the cleaned contacts and complete the circuit. The last piece is the lever. I want this little hollow area on the lever to fit around the lego jobbie. Now stop me if I get too technical. Last, I adjusted the position of the cleaned contacts on the bottom so the light goes on and off as I squeeze the lever (edited for technical terms 11/20/13).
    Jobbie     Jobbie magnified


  14. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.
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    But no minivans!


  15. Then I finished my beer.
    Beer


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Think: Cars are expensive, powerful, and heavy.   Before I start work, I face the possibility that I will destroy my vehicle, my own life, and innocent pedestrians' lives.   If anyone messes with a 4000 lb machine capable of 100 mph, these are real possibilities.   If I get in over my head, I call a professional mechanic.   The information on this website is provided only for entertainment purposes, and it is not intended as advice on how to service a vehicle.   For all you know I made this up.   Don`t believe everything you read on the internet.

Disclaimer: The technical information in these documents is provided without any warranty whatsoever and at no cost.   All information is in general terms and is not meant to apply to your particular situation, be current at the time you read it, or even be correct in the first place.   Improperly maintained vehicles can lead to serious injury, death, or unavoidable accidents. The author is not responsible for any errors on this site, and does not make any claim at all about the validity, safety, or veracity of the information contained on this website. Any work you choose to do or not to do on your vehicle is done at your own risk. The information on this site is not intended to serve as a replacement for professional advice, professional workmanship, dealer service, union labor, or psychological counseling.   The author disclaims any and all liability directly or indirectly arising from the application or use of any information or idea contained on this or any other web site.   By opening this page, you agree to never sue anyone ever or allow anyone to be sued on your behalf.   The appropriate professional should be consulted regarding your specific condition.    BeerGarage.com does not take responsibility for the information posted on other sites to which it links.

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Last modified: 11/25/2014
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