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Thread: Disassembly of Headlight Switch

  1. #1
    3 Red Bricks
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    Disassembly of Headlight Switch

    To remove headlight switch, lift fuel tank and disconnect the large connector that is on the left of the frame center tube. Cut any wire ties that are holding the wire in place.
    P1000783.jpg


    Remove this screw that holds the switch to the clutch perch and lift up.
    P1000766.jpg

    Put switch on bench and remove this screw to release the turn signal button.
    P1000767.jpg
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

  2. #2
    3 Red Bricks
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    Pull turn signal button straight out. You might have to wiggle it a bit because it is snug.
    As of this time, new turn signal buttons are still available: 61 31 9 062 462 SET: REPAIR KIT FLASHER KNOB $7.06
    That's for the pair (left and right). Other buttons are only available new by buying the complete right or left switchgear assembly ($174 per side).
    P1000768.jpg


    Remove these three screws fom this cover.
    P1000769.jpg


    Remove cover.
    P1000770.jpg
    Last edited by 98lee; 08-31-2015 at 09:21 PM.
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

  3. #3
    3 Red Bricks
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    Remove these two screws.

    P1000771.jpg

    With the horn button just above your bench, remove this screw while gently pushing on it. This will allow the horn button to drop on the bench or into your hand if your hand is under the switch.
    P1000772.jpg

    This is what the horn button looks like.
    P1000773.jpg
    Last edited by 98lee; 08-31-2015 at 08:38 PM.
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

  4. #4
    3 Red Bricks
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    This is the horn button with the spring, plunger, and screw layed out like they go back together.
    P1000774.jpg

    Since the horn switch pivot is flared after assembly, further disassembly of the horn switch is not advised. This is the area that you want to clean with contact cleaner and compressed air. You can see the contacts in this gap.
    P1000775.jpg


    Position headlight switch in "Flash to Pass" position and remove this screw.
    P1000777.jpg
    Last edited by 98lee; 08-31-2015 at 08:51 PM.
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

  5. #5
    3 Red Bricks
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    With a small pin punch or nail, push out the headlight button pivot pin (it's not tight).

    P1000776.jpg


    Remove button from switch.

    P1000778.jpg


    Carefully (slowly) remove headlight switch rocker assembly, trying to avoid scattering pieces (contact plates and springs). Here is the removed rocker assembly.

    P1000779.jpg
    Last edited by 98lee; 08-31-2015 at 11:10 PM.
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

  6. #6
    3 Red Bricks
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    This is the headlight switch rocker assembly laid out the way the pieces go back together.

    P1000780.jpg

    This is the typical gunk that you will find on the headlight switch contacts.. This should be cleaned off.
    P1000781.jpg

    These are the four contacts inside the housing that should also be cleaned. A SMALL amount of dielectric grease (for lubrication purposes) can be added. These contacts are what fails when high amperage headlights (or even running high beams all the time) can cause these contacts to get hot and recede into the plastic so they no longer make contact. Eastern Beaver makes a very nice relay assembly for these bikes that eliminates this problem.
    P1000782.jpg



    Have fun!
    Last edited by 98lee; 08-31-2015 at 11:11 PM.
    LONG MAY YOUR BRICK FLY!

    Ride Safe, Ride Far, Ride Often

    Lee Fulton Forum Moderator
    3 Marakesh Red K75Ss
    Mine, Hers, Spare

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