Yesterday I read about the recall to replace the rear brake light switch on 2009-2011 Touring models. From what I understand the issue is heat degradation of the switch resulting in switch failure.

HDs fix is to replace the switch with a newer version. I assume this newer version is more heat tolerant than the original, but that still doesn’t address the root cause of the problem. It wouldn't surprise me if these new switches start failing in the future, because from what knowledge I currently have on this issue, it doesn't seem to me that HD has addressed the root cause.

If heat is the issue, then minimizing that heat is the most appropriate corrective action in my opinion.

Following that train-of-thought, I went out to the garage and took a look at the location of the brake switch on my '11 Limited. The switch mounts to the frame directly adjacent to the exhaust header (and catalytic converter) with just over an inch between the two. It’s quite obvious where the heat is coming from. Common sense tells me that protecting the switch from the heat source should solve the problem.

So that’s what I did. This morning I spent just over an hour fabricating a heat shield to protect the switch. See attached pics. I still need to paint the heat shield – I took these pictures prior to paint so it would be easier to distinguish the shield in the pictures. Once it’s painted black it will not look out-of-place at all.

It’s a pretty simple way to get some additional insurance against experiencing a switch failure in the future with either the original switch or the newer version if you’ve had it replaced, or are going to have it replaced. I’m undecided whether I’m going to take my bike in for the newer switch or not. I’m leaning towards just leaving it the way it is. My reasoning is that I removed the cat early on so my switch has not seen the extreme heat as those on a stock bike would, and the heat shield will provide for even less heat in the future.

 

Looks like a good idea!

 

If you are going to market it I'll take one.........

 

Neat idea , just one bolt correct?
I've got some aluminum sheet laying around , gotta get to work.
Very nice.....
Mick

 

Me too!

 

Yeah, one bolt. Plus one nylon tie-strap. Both were existing so there is absolutely no permanent modification necessary. The bolt is the one that holds the bracket/fitting that the switch screws into to the frame, and the zip-tie goes around the same bracket and the frame holding a wire harness. Just had to drill a hole in the shield for the zip-tie.

 

thumbs up

 

Just one bolt for mounting , 1 zip tie for stability , very clever.
Nice job.
Mick

 

Here's a few pics of the finished project. Glad I took the pictures earlier before painting the heat shield - you can hardly make it out in these pics now that it is painted.

Aside from paint prep, painting, and waiting for the paint to dry this was about a two hour project.

 

What material was used for the heat shield? It was suggested by another forum member to use aluminum sheet goods, such as roof flashing, perhaps?

Does aluminum reflect heat or conduct heat? If it conducts heat, then would a remedy using this material actually move the heat closer to the switch? Would the aluminum shielding box in any heat in and around the switch? If the answer is 'yes', then it may be better to leave things be and have the recall work done.