So I pulled the rear off my SDR to install inserts in my FMF exhausts and when I put the bike back together my brake light appears to be stuck on all the time. Applying the front or rear brake makes no difference, the tail light has the same intensity. I checkd and double checked the connections and everything looks fine. The plug only goes together one way so that can't be it. I'm hoping I'm just overlooking something really stupid ...anyone have any ideas? I'm ok with the the mechanics of a bike but not so good with the electrical stuff

Either the switch is stuck meaning always bright or the second filament in the bulb is burnt out meaning it's always dim. Since you had the rear off, I'd lean towards the second. You could put a multimeter on the bulb socket to see if one of the terminals has voltage when the brakes are on but no voltage when the brakes are off.

So as it turns out its not a problem with the brake light connection. It appears the brake handle is not triggering the brake micro-switch when in the off position so the micro-switch isn't fully depressed thinking the brake light should be on.

I've tried adjusting the brake lever pull but that does nothing. The post on the lever makes contact with the switch button but not enough to trigger it, i can't see any way to adjust the brake post or the switch position...am I missing something? I can build up the post with some electrical tape for a temporary fix but any ideas are welcomed. My SDR only had 2,500 miles on it when I bought it so it's hardly a wear issue.

Thanks--Scott

I think you're missing something!
If the pin doesn't make the switch the brake light shouldn't come on at all!
There are 2 brake switches, one on the front brake lever and one pressure switch on the rear brake master cylinder, test both with a multi meter.
It is also possible that the micro switch has corrosion or water in it so it stays on.

AS KTM Guy says the front brake switch is drepressed when the light is not on. When you squeeze the lever the switch releases, the circuit is completed and the light comes on. Are you sure it hasn't dropped off the master cylinder? Its fitted underneath.

I also have this problem ( random, not always so haven't fixed it yet ) of after braking the light doesn't go off.

But for me it's the switch that's faulty, once you brake it doesn't go off. Going to have to buy a new one I think

Guys, it's the front hand brake lever that is in question and as you noted (and I apparently didn't describe very well) the post on the brake lever is not applying enough pressure to the micro-switch to fully engage it when the handle is at rest. In other words, the switch thinks the handle is being depressed and the brake light is on constantly. The post that triggers the switch when the brake handle is released makes contact with the switch but just barely, not enough to actually trigger it. If I operate the switch manually it works just fine, the brake light goes out when depressed and on when released, just as it's supposed to.

I notice I have aftermarket levers compared to the pictures I've seen of the stock ones. Mine are black, marked KTM, collapse and have a brake lever adjustment knob mounted on the clutch side for on the fly adjustments. They are marked KTM though so perhaps they are part of KTM's accessory line, I'll take a look. Regardless, I guess I can order another switch but I'm afraid it will be the same problem since the switch itself works fine it's just lack of enough contact that won't trigger it. I don't see a screw to mount the switch, does it just snap on and off somehow, I'm always cautious of prying and pulling something we're not familiar with, especially electronics (you should see the mess I made of the ECU plug under the seat before I figured THAT one out )

Ok, I found this post from another member (boney95) here a couple of years ago -->

Thanks guys. I figured it out the other day. I went out and bought a nice multimeter tester and checked the plug that runs from the bike. It checked out good. So then I FINIALLY started to think. I put on a set of ASV's a couple of days prior. I looked at the front brake lever and sure as shit, the stopper on lever that pushes in the button on the switch was not fully depressing it. Thus the brake light was full on the entire time. Dumb ass! Took the lever off and adjusted the stopper. All is good now. I do stupid shit like this sometimes. Don't ask me why I didn't check for this when I first put the lever on.

This is exactly the issue I'm having, I'll look more closely and see if there's any way to adjust that post short of bending (and breaking) it.

I have the same levers on the same bike and they work fine with the OE switch - your pin is simply stuck in the in/on position - WD40 and carefully pull the pin into the out/off position - at worse, just replace the switch.

$54 for a brake light switch? I thought Triumph parts were pricey

$75 for the clutch switch...........