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[MyCVOHarley]

Well we all know the recall for the brake lamp switch is due to the heat. The heat is due to poor air flow. I have the Fullsac exhaust system so the heat is not as bad. I do have some melted wiring loom under the engine on the right side. Talking to Steve at Fullsac I found I should always keep my vents on my lowers open and there are some modifications I chose not to make to my lowers. I just ordered some heat exhaust wrap from Summit.com part number THE-11620. I plan to wrap my collector under the chrome shield. The heat on my leg is no longer a problem but the melting wires is a big problem. I'm open to any ideas anyonemay have. We need more air flow. 
Thanks..

[GregKhougaz]

Before you wrap that heat shield, you might want to read this thread:  Exhaust wrapping under heat shields?  You might want to consider a ceramic coated head pipe instead...  Just a thought.  I realize it's more $$.

[MyCVOHarley]

I have the Fullsac head pipe on it now. Don't know what its coated with. Maybe I should wrap the wiring instead. Thanks for the link for that thread.

[firefighter156]

Had mine done today. Took about 30 minutes. I watched them hook up this portable hand held computer thing to activate the ABS and bleed the brakes. All is good. Works perfect. Mechanic (who is actually a good one) says the failure has absolutely nothing to do with the heat from the exhaust, It has everything to do with the heat being generated within the switch itself that is failing. He also said the ONLY reason the edges are beveled on the new switch is so that from just a quick glance you can tell the switch has been replaced.  ??

[Twolanerider]

What is the source of this internal heat generation?

[Aussie]

It has everything to do with the heat being generated within the switch itself that is failing.

Not being an electronics person what would cause the switch to overheat if it was cause electricaly.
Under engineered in the circuit department!!! 

[firefighter156]

Not being an electronics person what would cause the switch to overheat if it was cause electricaly.
Under engineered in the circuit department!!! 

Unsure.  He stated he just worked on one where a guy was traveling thru some twisites in the smokey mountains and was overusing/dragging the rear brake and it lit up and burnt out??

[firefighter156]

I know if you look at the switch on a 2007 and prior the switch itself is quite bigger.  He also said after 2007 they had 2 more subsequent changes that resulted in the size it is today.  perhaps the reduction in size, coupled with maybe a new supplier (likely cheaper) results in a inferior part??

[grc]

As for that mechanic who claims the problem is not related to the radiational heating from the exhaust and engine, but just internal heating from the switch itself, I'd like to know how he came to that conclusion.  Did he test some switches to failure by operating the brakes continuously with the engine off perhaps?  Funny how the same switch, p/n 72023-51D, is also used on Softails, but Softails are not part of the recall.  Of course Softails have a totally different exhaust system.  Maybe Softail riders don't use the rear brakes very much.  Or maybe that guy would like to reconsider his BS "theory". 


Jerry

[firefighter156]

As for that mechanic who claims the problem is not related to the radiational heating from the exhaust and engine, but just internal heating from the switch itself, I'd like to know how he came to that conclusion.  Did he test some switches to failure by operating the brakes continuously with the engine off perhaps?  Funny how the same switch, p/n 72023-51D, is also used on Softails, but Softails are not part of the recall.  Of course Softails have a totally different exhaust system.  Maybe Softail riders don't use the rear brakes very much.  Or maybe that guy would like to reconsider his BS "theory". 


Jerry

LOL!!  Not sure.  Just passing on the claim he made.  He is typically pretty reliable but maybe he's off the mark on this.  Maybe another mechanic or indy will also chime in?

[timo482]

a ford brake switch - including the one on my f350 has burned down a whole bunch of houses, now i have the "fix" that is supposed to make the brake circuit quit working rather than burning the house down with the truck

in any case - bad brake light switches that burn cars up have been around for a LONG time

and hd switches look basically the same

to

[djkak]

It has everything to do with the heat being generated within the switch itself that is failing.

a ford brake switch - including the one on my f350 has burned down a whole bunch of houses, now i have the "fix" that is supposed to make the brake circuit quit working rather than burning the house down with the truck

in any case - bad brake light switches that burn cars up have been around for a LONG time

and hd switches look basically the same

to

I am sure that the only load on the hydraulic brake lamp switch is from the relay that energizes the brake lights; pretty low load.
 
The brake lamp circuit is not energized when the ignition is off.

I did notice something interesting the other day. If you shut off the ignition on a late Softail while you are still moving, the instrument panel oil and neutral lights stay on until the machine stops moving.

[MyCVOHarley]

I find it odd that the problem only applies to all touring models with the crossover under the bike. And all those bikes have heat problems, more so the CVO....

[jagerbomb]

I have been having an occasional problem of loss of power during semi aggressive riding. I removed the doors on my lowers and it seemed to go away. While coming back from Fayetteville a couple of weeks ago even with the doors removed it got substantially worse and I had about 6 separate occasions of substantial loss of power like it was dropping a cylinder.As I would start to pullover the exhaust would cool and the problem would go away.  Tonight while working on the bike I pushed on the brakes and the brake lights stuck on. I'm wondering if the ECM is seeing the brake input and reducing power like in a car with throttle by wire? When I get it back together I will test my theory.

Mark

ps I'm calling BS on the tech who thinks that the switch is causing that much heat to be a problem( he's a dips**t ) Look where the switch is in relationship to the exhaust.

[FatTom]

Shield for brake switch:

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=280779930174&category=35557&_trksid=p5197.c0.m619