Figure 6-86. Rear stop lamp switch: XL models only: 1. Rear brake line; 2. Tee nut; 3. Rear stop lamp switch; 4. Spade connector terminal socket (2) [121]
XR 1200X: The rear stop lamp switch is located underneath the motorcycle near the rear brake master cylinder reservoir. The rear stop lamp switch threads into a tee nut in the rear brake line.
The stop lamp switch is an open type switch which closes with hydraulic pressure. When the pressure in the line reaches a preset level, the rear stop lamp switch closes and the rear stop lamp illuminates.
Note. This part cannot be repaired. Replace upon failure.
Replacement
| FASTENER | TORQUE VALUE | |
| Stop lamp switch to tee nut | 132-168 in·lbs | 14.9-18.9 Nm |
| Brake master cylinder reservoir, rear, mounting screw | 20-25 in·lbs | 2.3-2.8 Nm |
1. Remove main fuse.
2. XL Models: move rear brake master cylinder reservoir out of the way:
- a. Remove the rear brake master cylinder reservoir cover. Grasp cover and pull straight away from reservoir.
- b. Remove reservoir mounting screw and secure reservoir upright out of the way. See 2.13 REAR BRAKE MASTER CYLINDER RESERVOIR.
3. See Figure 6-86 or Figure 6-87. Pull terminal sockets from spade connections (4) on stop lamp switch.
Figure 6-87. Rear stop lamp switch: XR 1200X: 1. Rear brake line; 2. Tee nut; 3. Rear stop lamp switch; 4. Spade connector terminal socket (2) [121]
4. Remove stop lamp switch (3) from tee nut (2).
5. Thread new stop lamp switch (3) to tee nut (2) on brake line. Tighten switch to 132-168 in·lbs (14.9-18.9 Nm).
Note. XR 1200X: Make sure that the brake switch wires do not contact the ground strap cable.
6. Install terminal sockets on switch spade connections (4).
7. XL Models: Install rear brake master cylinder reservoir:
- a. Replace the reservoir mounting screw. Tighten to 20-25 in·lbs (2.3-2.8 Nm).
- b. Replace the brake master cylinder reservoir cover.
8. Install main fuse.
9. Install left side cover.
10. Refill master cylinder and bleed brakes. See 2.17 BLEEDING BRAKES.
Warning! After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury.
11. Test operation of rear brake.
Warning! Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury.
12. Test operation of stop lamp with the rear brake applied and the ignition/light switch turned ON.