flaky handlebar headlight switch

[burntstick]

91 k75 rt ,140000 kms ,alberta has flaky handlebar headlight switch . Guess is its worn out and needs replacing. Anyone disassembled / repaired successfully ? Thanks

[enb54]

91 k75 rt ,140000 kms ,alberta has flaky handlebar headlight switch . Guess is its worn out and needs replacing. Anyone disassembled / repaired successfully ? Thanks

There are several threads on how to disassemble and reassemble the light switch and this http://www.motobrick.com/index.php/topic,824.0.html is a start, suggest that you search and read articles first. I had a tough time with the same issue and sort of got mine cleaned (small easy to lose parts) and then decided to use the switch to operate relays, which is what BMW likely should have done in the first place. The high current through the light switch is not good for longevity, so even if you replace the switch (very expensive) you should consider installing relays... Just some initial advice, I'm sure others will chime in with more...

Edit: Have a peek at http://www.k100-forum.com/t174-headlamp-switch-repair on the K100 forum...

[The Mighty Gryphon]

Google "Eastern Beaver".  He sells a beautifully built plug-in harness for headlight relays for about $55. 

Not only will your handlebar switch last longer, but the light will be noticeably brighter as well.

[riots100]

This was the first issue that I fixed on my K75 when I acquired it. 


The switch contacts probably have carbon built up on them from handling the current load of the headlamp.  I cleaned off the carbon with a small wire brush, a small jewelers file and spray contact cleaner.  Then I installed a Headlight Relay harness from Eastern Beaver (http://easternbeaver.com/Main/Wiring_Kits/H4_Kits/h4_kits.html) to take the current load off of the switch.


It has been perfect since.

[burntstick]

Thanks to all respondents for great advice ! Great forum supported by great brickers!
A great winter read - Jupiter's Travels by Ted Simon ---63000 miles ,4 years,54 countries,1m.c.

[woodgeek]

Google "Eastern Beaver".  He sells a beautifully built plug-in harness for headlight relays for about $55. 

Not only will your handlebar switch last longer, but the light will be noticeably brighter as well.

Thanks for the great tip. I just disassembled my headlight switch to clean it as it was inoperable--I didn't want to shell out $135 for a new one and this will surely extend the existing switch's life.

[beemrdon]

Awesome. My second switch is acting up now. Looks like the Eastern Beaver set up is good for more than one problem. I want to run a more powerful halogen bulb too.