How to adjust the front brake lever switch?
 

Hi there,

Can anyone tell me how to adjust te front brake lever switch for the brake light.
At this moment i have to squeeze hard before the brake light lights up.

In the manual i can find how to adjust the rear brake light switch, but not how to the front brake.

thanks...

The front brake light switch is not adjustable. There are a couple of things you can try though.

First check that the switch is mounted solidly and isn't moving in its housing. Particularly check the retaining pin/clip, which can get sloppy over time. Also check that the actual lever pivot hasn't got too much play in it because that can cause poor brake light operation.

Next try using contact cleaner (or alcohol based brake cleaner), squirting it into the the gap around the plunger (you might be best removing the lever to gain access). Push the switch in and out, spray some more and keep repeating. This may bring the switch back to life if it's dirty contacts causing the late operation.

If that doesn't work you can cut/nibble a bit of the end of the plunger, so when you pull the lever the plunger starts to move out earlier.

Failing all that you may have to resort to a new switch, they do wear out and are exposed to a lot of road spray and damp. They aren't expensive, I think they are about �15 (18 euro). However, as long as it operates (however hard you have to pull the lever) it is legal.

I adjusted mine as it was the same as yours and wanted a brake light to show as soon as I squeezed the lever
I never thought of taking a tiny amount off the plunger
I milled a small indentation into the lever, der
It is only a very tiny amount you need to remove though
I'd use sandpaper and keep trying it till right, if you cut to much off, it's a new switch

Info like this can be found in the modification index or my mod book . http://www.xt660.com/showthread.php?t=630

Back in 2008> http://www.xt660.com/showthread.php?t=7612

I cleaned the inner switch and filed 0.5mm off(like the mod).
The switch workes fine now...

Thanks..

Nice one.

same over here
 

I noticed this this when the bike was in warranty. took it to the dealer. they had a mechanic very experienced on this bike who said it was a common problem. filed away the top of the plunger as in kev's instructions & problem solved & a happy customer