Headlight Switch (European Style)

[jhinds434]

Thanks.

[melville]

If it's just the high 'n' low beam that has failed, I have a fix that runs $30 for a relay + a bit for some wires. Head to my resto thread for some guidance:

viewtopic.php?f=1&t=148&start=140

[jhinds434]

handlebar).

[melville]

Thanks Mel. The combo switch, @180 plus dollars U.S. is really hosed. I don't think a relay will fix. I need to get into the switch to diagnose/repair, or just replace it with another soon to fail part. Part 61311243248 I think.
But, I'll visit your link though I'll allow I don't see how a relay can be a work around repair for a defective combo switch that makes a dead short on high beam resulting in smoke coming off the wires in the switch (seen when unattached from handlebar).

The relay keeps full headlight current out of the switch, and only requires momentary energization of the switch. The stock setup runs full headlight power through the dip switch at all times.

You may be able to use the 'passing beam' part of the switch to get that momentary energization. In this case, it would mean using the red and white wires to get power from S to ground.

Good luck!

[dwerbil]

Welcome to Boxerworks jhinds434. What part of Tejas are you
located? I"m just north of Austin.

[jhinds434]

Mel, If I had your level of expertise with electronics I MIGHT try your remedy. On the other hand, I like the idea of keeping the bike as stock as possible. I just hate giving up on taking the stock switch apart and trying to repair it. I'm pretty sure someone, somewhere has tried this, problem is, finding them. Having said that, your idea has some attraction, and I guess you were facing a similar problem when you decided to install the VW relay under the gas tank as a work around. Thanks.

[jhinds434]

the Boxer.

[justoneoftheguys]

Mel, If I had your level of expertise with electronics I MIGHT try your remedy. On the other hand, I like the idea of keeping the bike as stock as possible. I just hate giving up on taking the stock switch apart and trying to repair it. I'm pretty sure someone, somewhere has tried this, problem is, finding them. Having said that, your idea has some attraction, and I guess you were facing a similar problem when you decided to install the VW relay under the gas tank as a work around. Thanks.

Do yourself a favor and get that current out of the switch.

And if you DO decide to take the switch apart, do it inside of a large plastic bag.