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Old 11-29-2009, 03:21 PM   #1 (permalink)
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I did a lot of trouble shooting and thought it was a sticking start/reverse button. I cycled the start/reverse button numerous times and the headlight came back on. But when I went to start it again the headlight wouldn't work again. I have repeated this process numerous times but really need to fix the problem. Any ideas?



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Old 11-29-2009, 04:05 PM   #2 (permalink)
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It may be the Hi-Lo switch. I have had the same problem with mine.

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Old 11-29-2009, 04:09 PM   #3 (permalink)
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Dis assemble your switch housings and clean them with contact cleaner would be first step I would take
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Old 11-29-2009, 05:39 PM   #4 (permalink)
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Thanks AspectOne. I will give that a try. Have a great night.
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Old 11-29-2009, 10:00 PM   #5 (permalink)
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The fact that fiddling with the switch helps make me agree with Aspect One.

Keep in mind there are lots of little parts inside that switch. Keep track of where things go.

Mine required disassembling the actual button and re-working the spring. With 115k miles, you may need to do the same.



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Old 11-30-2009, 07:20 AM   #6 (permalink)
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Yip, Your problem will be solved by just opening the switch and clean it out with a electric contact spray.
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Old 12-02-2009, 12:42 PM   #7 (permalink)
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Okay.....Inside the switch housing is interesting. There is a "ball shaped" piece of metal with a wire attached to it just under the "set/decel" switch housing. It makes contact with a small circular metal spot that is part of the start/revese switch. It looks like this "ball" is only held in place by pressure from set/decel switch housing. Seems like a poor design to me if it is. I couldn't locate an illustrated breakdown pf the switch.

I also found that when the switch sticks I can pull it towards me and the Head light comes on and stays on unless I cycle the switch again.
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Old 12-02-2009, 01:05 PM   #8 (permalink)
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Got to be a spring involved. You sure the attached wire isn't spring steel?

Can you post a pic?
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Old 12-02-2009, 01:22 PM   #9 (permalink)
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I thought intermittent/flashing lights were a feature - not a bug.
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Old 12-02-2009, 01:23 PM   #10 (permalink)
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check the big connector behind rt knee panel
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