2003 610 Brake issue

Discussion in '610/630' started by supergper, Sep 28, 2009.

  1. supergper Husqvarna
    AA Class

    Location:
    Riverton, UT
    Right now my brake light is always on. I've tracked down the issue to the front brake switch. It's just hanging there. Where does it go? I can't seem to be able to find any holes, clips, etc that could possibly hold it. Can anyone point me in the right direction? Just got my bike this weekend so this is all new to me. :thumbsup:
  2. Norman Foley Husqvarna
    Pro Class

    Location:
    Trumansburg, NY... The Beautiful, Finger Lakes
    Husqvarna Motorcycle:
    82 250WR 86 250WR 93 WXE350 03 TE610
    Other Motorcycles:
    '85 Fantic 300 '12 HUSABERG TE250
    On my '03 TE610E it runs in front of the reservoir and plugs in in front of the lever pivot bolt.
  3. petem Husqvarna
    A Class

    Location:
    Andover, UK
    That happened to my TE450 a couple of weeks back and it took me a few seconds to see where it came from. If the 610 has the same brake assembly there will be two holes on the inboard (left) end of the assembly just in front of the handlebar (this photo is looking right from the middle of the bike along the front of the handlebars).
    View attachment 2096

    The switch has two small plastic pegs on the side which are a push fit into those holes. On the switch itself there's a plunger which sticks out near one end, and it should be fitted with that plunger to the front at the top. You may need to pull the brake on slightly to make room for the plunger as you fit the switch. Here's the same view but with the switch in place. You can see I've pulled the brake lever a little to make this end of it move out.
    View attachment 2097

    Once you release the lever the left end moves back and presses the plunger in, turning off the brake light. That's why it's on all the time when the switch is dangling - the brake lever isn't pushing the plunger in as it normally would.

    Easier to do than to describe! :thumbsup: But if yours is different this may not help...

    Attached Files:

  4. supergper Husqvarna
    AA Class

    Location:
    Riverton, UT
    It's actually a bit different than your TE450. It's as Norman described above, just a single hole that threads in. My threads ended up being broken off. I was able to unscrew the broken threads and I'm trying to super glue them back on. :fingerscrossed: :D

    Thanks for the quick responses guys.