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HI/LO Light Switch Repair
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HI/LO Light Switch Repair 18 Jul 2022 12:41 #870564

  • hardrockminer
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I'm currently rebuilding a few controls out of spare parts I've acquired.  One part is impossible to find in good condition.  Does anyone have a source for the switches for the HI/LO headlight switch?  Alternatively, does anyone repair them, and if so....how?

 
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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HI/LO Light Switch Repair 18 Jul 2022 13:44 #870567

  • Wookie58
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Maybe one of the geniuses on here can scan and 3D print a replacement ?

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HI/LO Light Switch Repair 18 Jul 2022 14:20 #870569

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The little piton at the top is the weak point.  It has a hole drilled into it.  This makes it a weak point.  The top breaks off.

Metal would be much stronger.
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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HI/LO Light Switch Repair 18 Jul 2022 14:47 #870571

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The little piton at the top is the weak point.  It has a hole drilled into it.  This makes it a weak point.  The top breaks off.

Metal would be much stronger.
I see what you mean, not sure how you would insulate the contacts though !! 

Maybe you could print it with a recess in the back so you could bond a metal actuator to the back of it ?

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HI/LO Light Switch Repair 18 Jul 2022 18:37 #870585

  • Mikaw
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I have one, it’s your. It has a crack at the top of the screw hole. I bet you could superglue it. 

 

 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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HI/LO Light Switch Repair 18 Jul 2022 18:54 #870586

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PM sent
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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HI/LO Light Switch Repair 18 Jul 2022 19:17 #870589

  • hardrockminer
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Mikaw, you're a regular Dick Tracy!  Thanks for your help.
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.
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HI/LO Light Switch Repair 19 Jul 2022 22:06 #870683

  • stone fruit
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Scroll down for replacement part
Blank Page (redlinecycle.com)

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Last edit: by stone fruit.

HI/LO Light Switch Repair 20 Jul 2022 04:19 #870699

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Scroll down for replacement part
Blank Page (redlinecycle.com)
Ouch!  Them aren't cheap!  But thanks for the link.
I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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HI/LO Light Switch Repair 20 Jul 2022 06:35 #870706

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I had few over the years. One of those cans you just throw all the small parts into. Looks like a winter project?? Might have to mill a small chunk of aluminum out, make a small mold for some liquid setting epoxy?
Marty in Buffalo
Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Last edit: by z1kzonly. Reason: spell check

HI/LO Light Switch Repair 21 Jul 2022 14:46 #870800

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Anyone want one? Let me know. If your bike is a keeper? And it's cleaned and ready to go? You have this problem? Fit the broken one on. Then stick a wad of your favorite Glue? Sealing agent? Epoxy? Bubblegum? Into the knob on top. Glue it all together for a permanent fix! This way it won't fly off if you ever blast it over a 100 mph. Or so?
Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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HI/LO Light Switch Repair 22 Jul 2022 00:12 #870826

  • Kidkawie
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Buying NOS is a waste of money.  I bought two in the past year, both broke within one or two rides.
Im trying to repair this last one making it wider.  Ill fit the button on when it arrives.  Luckily those buttons are still cheap.

 
1975 Z1 900
1994 KX250 Supermoto
2004 KX125
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