I’m currently servicing a mates kids posty bike. All good except for front brake light switch. Replaced the switch and no matter how much I adjust the cable free play the brake lever won’t return all the way , leaving the switch engaged and brake light permanently on. I need to tighten the cable so the lever has no free play at all for the switch to automatically turn off . Any one come across this issue with these little bike before? Are these brake levers supposed to have a return spring ?
Return spring goes over the bare cable at the wheel, between the cable mount and lever. Any spring that will fit will do.
Thank heaps Murdo… spent the last hour rigging up a washer n nut to create a spring tensioner to increase the tension on the cable n spring. Problem seems to be solved
Yes, it’s funny, the spindly little spring Honda use here seems designed to fail…. I’m wondering how many of these little workhorses have intermittent brake light issues once the cables get a little stiff or the grease on the lever dries up slightly.
Surprisingly the spring (OEM one that is) isnt all that spindly.. it can be a right little cow to get the cable correctly into place and as long as the brakes and cable are well serviced then there shouldnt be an issue... there is always a caveat
Yes, I have no way of knowing if the spring on the bike I was servicing was original. It most certainly wasn’t up to the task. Absolutely no issue fitting the cable into the brake arm with it in place, even after lubing the cable, greasing the lever and adjusting the lever bolt, the brake light still only worked intermittently as the lever wasn’t returning all the way home when released. Anyway, all sorted now.