By Paul C
8-2004 Problem: Headlight switch very hard to move and dead spot where light goes off. Miles: 45,000. I live in a place where it never rains. Even though the switch is carefully enclosed, I think dust and dirt gets into it as you drive. I was surprised by the build up of dirt I found in my switch.
Thanks to the directions I followed from Don Eilenberger:
If you could buy this switch for $30 I would recommend it. My switch works well but it still has a flat spot. In the day it is not possible while riding to know for sure if my head light is on. Hopefully, I won't need to touch it for many years. It has been over a week now and the switch is working well.
Large clear plastic bag. Dielectric grease. Q-tips & hand cleaner or other light degreaser. Do not use strong solvents or brake cleaner. It will destroy the plastic. #2 phillips screwdriver. Very small straight screw driver to pry. Toilet paper or shop towels to clean in small places.
~ 1 - 2 hours.
Do not push or play around with the switch unnecessarily until full disassembly. The key part is the headlight button. Once removed the switch can be rotated up (see picture 4) even with the pin in place and the springs will shoot out!
The dealer quoted me $65 + tax for the switch. You should call your dealer first for price and availability. If you make a mistake and springs go flying you will need to buy a new switch - so get ready in advance.Disassembly:
Re-install all parts - keep covered with the bag until the headlight button is screwed in. Then you are safe from the springs popping. TAKE YOUR TIME AND DON'T RUSH.