This is actually for my 748, but I thought some of your experience here might help. Today I failed the state inspection [bang] because my brake light is not actuated by the front brake lever. The rear brake pedal works properly.
My initial idea was that the switch was not functioning. Switch cycles fine mechanically, moves, clicks, etc. If I follow the wires I reach a point where there are a set of disconnects. When I attach a multi-meter here it will cycle between 0 and infinite resistance as I cycle the brake lever. Therefore does not appear the be the switch electrically.
From there the wires disappear into the harness. I am going to do some more trouble shooting tonight. Has anyone dealt with this type of thing before? Any ideas where to start looking next? I think I will start working tail light forward. At some point it connects back to the rear brake too. Maybe the problem is there.
As always, thanks for your thoughts and all comments are appreciated!
Assuming the brake light works with the rear brake lever you will just have to trace the wires until you find the open. The front switch does go into a multiple connector. Do make sure the rear brake light works. If not, the problem could be the fuse or the bulbs,
I have found the answer to my own question. I checked power going into the switch and found 12V. From there I used a jumper to bypass the switch and Ta-Da . . . Light works. So it is the switch. Easy replacement, now I just need to find one.
I just fixed this problem on my '03 Monster 800ie. I did the same thing as far as bypassing the switch and verifying that voltage to the brake light is good. That left the switch as the culprit. I opened the tabs on the switch a bit, enough to wiggle off the cover of the switch. Then i checked the resistance of both posts of the switch, i saw some resistance, not fully open like it should be. I concluded that the contacts of the switch may be a little fouled. I used the bevel on the edge of a utility knife to "file" both sides of the contacts that are the moving parts that close the circuit. Just kind of lightly scuffed up the contacts so any corrosion would be removed. This fixed the problem.
The only problem, was that i lost the rod/pin between the handbrake and the switch, that would actually press the button on the switch. So i had to fashion a replacement out of a nylon bolt.
I hope this reaches you in time, cuz i didnt want to have to order a switch, and now all is well.
Good Luck!
Thanks for the heads up. I did order a new switch, but still have the old one so I will check that out. Where it was a "micro"switch, I didn't put a lot of effort into trying to open it and refurbish it. I should have known better since it already didn't work, what was the worst I could do? Break it? ;) That rod/pin is a PITA. I didn't even realize it was there until I installed the new switch and it wouldn't actuate. It took me a while to find where that little "extra piece" in the kit went. All is well now, and has been thoroughly road tested.
Glad you are up and runnin' and safely at that! :)