Winter tasks #1 - hi-beam switch

[manicguitarist]

The hi beam switch is faulty on my bayybbeee. I guess because it is rarely used - when I actuate the hi-beam, the switch doesn't then want to disengage. Leading to mucho twiddling with the button before it goes back to lo-beam.

Before I take it all apart:
Is this a common fault?
Anything in particular I should look for?
Is there a recommended fix?
Or shall I just take it apart and look-see?

Thanks dooods!

[royster81]

I've never heard of a common fault with the switch but mine is kind of sticky and I'm putting that dish to road grime.

Open it up and get a look at it

[manicguitarist]

I've never heard of a common fault with the switch but mine is kind of sticky and I'm putting that dish to road grime.

Open it up and get a look at it

Yeah, that's my feeling - lack of use and 20yrs of grit and grime has gunged it up.

I'll document the process with photos and stuff.

[royster81]

Nice one.

My 'passing' button was intermittent and I checked the wiring etc but until I opened it up if never have guessed what was wrong. The contacts on the button and the casing couldn't touch....

The button has a load of road rash on it so I can only guess that when the bike crashed and the button but the road it pushed the the button in and bent the contacts.

I bent them back and all is good

[Neosophist]

The hi beam switch is faulty on my bayybbeee. I guess because it is rarely used - when I actuate the hi-beam, the switch doesn't then want to disengage. Leading to mucho twiddling with the button before it goes back to lo-beam.

Before I take it all apart:
Is this a common fault?
Anything in particular I should look for?
Is there a recommended fix?
Or shall I just take it apart and look-see?

Thanks dooods!

if you are running h4s without the mod the switch can melt in some funny places.. when you clean it out check for any signs of melting if you are running h4 bulbs without a relay to drive the low beam.

not common anyway.

[manicguitarist]

The hi beam switch is faulty on my bayybbeee. I guess because it is rarely used - when I actuate the hi-beam, the switch doesn't then want to disengage. Leading to mucho twiddling with the button before it goes back to lo-beam.

Before I take it all apart:
Is this a common fault?
Anything in particular I should look for?
Is there a recommended fix?
Or shall I just take it apart and look-see?

Thanks dooods!

if you are running h4s without the mod the switch can melt in some funny places.. when you clean it out check for any signs of melting if you are running h4 bulbs without a relay to drive the low beam.

not common anyway.

I'll check that.
My bike now has the headlight mod (voltage at lights went from 11v to 14v) but was running H4s when I got it...so yeah, I'll check that.

[manicguitarist]

I fixed this yesterday - but I made the cardinal sin of not taking any pictures.


Anyways - unscrewed the switchgear from the handle bar using the 2 cross head bolts underneath.

Unsoldered the switch from the wires (note the solder is covered in insulating paint - but that didn't stop the unsoldering....just melted through it) and then took the switch into the kitchen with a cup of coffee.

For info - if you want to replace the switch with a generic one, you need a single pole double throw - but a DPDT with a bit of wiring would also work. The Honda switch is an odd one in that it is 2x SPST but with them reversed such that when one side is closed the other (independent side) is open.

Anyways - I figured I would see if I couldn't fix the switch - cos if I broke it I'd be no worse off and just have to buy a new switch and fit it in somewhere.

The switch is clipped together and came apart easily - I even caught the spring as it jumped out.

Predictably the switch was full of 20yrs worth of grime and thick almost solid grease. Cleaned the insides out with WD40 and put it back together - it worked! Yay!!

Resoldered and reassembled.

Total time - 2x cups of coffee worth.

:)

[yamahaha]

I find that mine occasionally sticks (runs h4s with the relay mod) and just give it a spray with wd or the like and problem solved