Main Motorcycle: Triumph Bonneville T120
Join Date: Jan 2018
Location: Draper, Utah, USA
Other Motorcycle: BMW R1200GS
I had the front brake micro switch come apart on my T120. I tried to find a replacement switch but couldn't. I even tried looking for the part on suppliers to Nissin as I guess it is their part as it attaches to what looks like their front lever casting. Anyway I took the whole cluster and cables in to the dealer and they replaced it under warranty. I know it is like $500 to replace the whole thing. Not cheap. They got the cluster and loom shipped in 24 hours, great service Triumph - especially all the way out here in Utah, 500 miles from anywhere.
Unfortunately the switch turns the brake light off when closed, so if the switch breaks your brake lights stick on. You can't just rely on the rear brake switch to activate the brake light. Well that was my observation anyways.
I was very careful when reassembling everything, it was easier from looking underneath the bars as it is very easy to damage the micro switch with the brake lever when you put it all back together. I think mine initially broke because the original lever was very rough on the surface where it contacted the switch, so over time it ended up breaking off the nub of the switch from sideways stresses.
I replaced the levers with the Triumph accessories ones. At least the left and right levers are now from the same vendor, unlike the originals it seems. They have very nicely machined surfaces where they contact the brake and clutch micro switches, so much better than the originals. OK, $250 I know, but they are a huge improvement in feel and operation.
I looked closely at the stock T120 levers. They look like the brake one is perhaps from Nissin and the clutch one from who knows where. Very different, very odd.
I just used the word break/brake/broke about 100 times...