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Rear brake switch loading

24664 Views 83 Replies 31 Participants Last post by  Vannack_Scrambler
Can it be true that the rear brake pedal rests on the brake light switch?

It seems that when the brake pedal is released by your foot it is the light switch that it then rests on.

The switch on this 2019 DS is held in by 2 plastic studs integral to the switch.

I can't beleive this is the design. Has something fallen off or has the job of the switch also been the stop for the brake pedal since inception.

Switch presently ty wrapped to it's holder because it likes nothing better than falling out.

I would have thought the pedal would have a stop that isn't the switch.

I guess I can wait til i see another DS but I'm thinknig of swapping the pedal anyway but this is a bit of a flaw that I need to design into the replacement?
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Thanks. I will likely just remove the old wiring and cut/splice/solder it. Guessing you just lost a little fluid from the line and bled it all out afterward.

Then I guess pull the old switch and make up a much more durable brake pedal stop so its not pulling the pin out of the master cylinder.
Thanks. I will likely just remove the old wiring and cut/splice/solder it. Guessing you just lost a little fluid from the line and bled it all out afterward.

Then I guess pull the old switch and make up a much more durable brake pedal stop so its not pulling the pin out of the master cylinder.
Yea bled it. Yea not much fluid lost at all.

Surprising when you unscrew the banjo bolt not much fluid came out. I think the fluid is held with some vacuum and friction from the fluid. But yea bleed it out I mean why not you’re right there and you do introduce some air into the system.

yea a better brake pedal stop is the way to go. I’ll get to it one day but I was itchy to get back out in the road after 3 weeks off.
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Interesting read. I’m going to have a close look at my bike this weekend to see if I can come up with a solution that leaves the stock setup intact. If I cant figure it out, the hydraulic switch sounds like a great mod.
Honestly after digging into mine and my issue I don't see a point in trying. That switch doesn't even look like it can be properly waterproof over time.
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Here are some high res pictures in case someone wants to do it themselves.

The location of the 3 bolts, the rubber grommet to get the cover off and the plug youll unplug:
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The location better of the two on the undertray:
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Where I Just cut the wire and left the old sensor, I cut it all off since mine was already broken two months in, Ill eventually remove it and put in a steel brake pedal stop.
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Here is the plug end with wires, as noted you'll just cap off the blue one. Ive already thrown some head-shrink on there. One to cover my splice and another at the top to seal up the end, I have had a history with ducati wiring and getting dirty/wet so Im aggressive with the sealing AND jamming dielectric grease anywhere I can
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The sensor end, nice thing is under the nipple its well sealed with a hardened urethane:
Wood Audio equipment Kitchen utensil Cable Wire stripper

I soldered mine, hopefully wont be dicking with this again (dont forget to put the heat shrink on beforehand):
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Brush the bare copper with some dielectric and heat shrink over the soldered joint:
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And then another over that as an abrasive layer and to protect from water (also jammed with grease):
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Now that we have a sensor:
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Remove the two bolts from the peg and put them back in to support the brake and exhaust while you work, also gets you clear access to the banjo bolt:
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NO DRIPS ON THE PAINT!
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Make sure and use the new washers that came with the kit, they are thicker and are needed for the longer bolt. Snug the new bolt in, run the wire up behind the brake line, behind the frame, get it inside the metal hook so it wont touch the exhaust, plug it in, zip tie any excess:
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Test, bleed the rear brakes (you will have introduced air into the very beginning of the system so run a lot through, you will eventually get a bubble), the put everything else back where it came and Bobs your uncle!
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Now I just need to fab up a bracket that will replace the broken switch as a stopper for the pedal. And it looks totally factory, I bet I could take it into the dealer for service and they wouldn't even notice.
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I should note, all of this was done while eating a sandwich over my lunch break today...
I should note, all of this was done while eating a sandwich over my lunch break today...
Great detail in your write up. Thx for sharing. Mine hasn’t broken yet but this looks like a perfect fix. I use double wall heat shrink with sealant and it keeps connections corrosion free.
Guess we should take everyone elses info and my pictures and make a how-to for the forum.
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Here is the plug end with wires, as noted you'll just cap off the blue one. Ive already thrown some head-shrink on there. One to cover my splice and another at the top to seal up the end, I have had a history with ducati wiring and getting dirty/wet so Im aggressive with the sealing AND jamming dielectric grease anywhere I can
View attachment 50810
The sensor end, nice thing is under the nipple its well sealed with a hardened urethane:
View attachment 50811
I soldered mine, hopefully wont be dicking with this again (dont forget to put the heat shrink on beforehand):
View attachment 50812
Brush the bare copper with some dielectric and heat shrink over the soldered joint:
View attachment 50814
And then another over that as an abrasive layer and to protect from water (also jammed with grease):

[/QUOTE]

Can you explain more about the wiring? You mentioned capping off the blue wire of the OEM switch, but how do the other wires match up with the new switch?

Thank you very much for this post, it's something I've struggled with on my 2019 Desert Sled.
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Just cut off the blue, seems to not do anything. The black and brown ones are just an open/closed circuit. I put brown to black on the other switch and blue to the other one. Its a simple two wire switch.
Just cut off the blue, seems to not do anything. The black and brown ones are just an open/closed circuit. I put brown to black on the other switch and blue to the other one. Its a simple two wire switch.
Thanks!
What is the pitch of the hydraulic brake light bolt?
1mm.
I installed this one and it works like a charm!
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Thank you so much for getting back to me. I've only had the desert sled for several weeks and before I decided to write it I was going to get all the accessories put on it including taking the wheels off and making them tubeless. I got all of that accomplished and I was ready to take it out for a good ride but noticed that the rear brake light didn't activate with the rear brake but worked fine with the front brake. Talked to the dealership and they said that this was a problem they've seen a lot of. So I guess instead of taking it out for a ride I will be making the conversion as soon as the parts come in. Would've been nice to have this taken care of if I would've known about it whenever the wheels and everything we're off and I was putting on the skid plate etc. Live and learn I guess
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It's an easy mod, just remove passenger footpeg bracket and the right hand side sidecover and everything is within reach :)
Yeah I didnt even have to take the brake lever off, just used some side cutters to snip the wire and left the stock switch there as the lever stop (eventually Ill fab up a metal bracket to server as a more positive/durable lever stop)
Yeah I didnt even have to take the brake lever off, just used some side cutters to snip the wire and left the stock switch there as the lever stop (eventually Ill fab up a metal bracket to server as a more positive/durable lever stop)
When you do that please take some photos
When you do that please take some photos
EXACTLY, some photos pls. If the hydralic option is the solution, where is it in the whole set up? I get the idea. Throw out the old OEM switch and order the part on ebay/amszon and hook it up. But where, and how? Picutres would be very helpful. Thx
My pictures on April 4 post #66 not loading?
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