Decided to repair the left and right side switches last night before installing new drag bars. The PO had mutilated the wiring, so I had my work cut out for me. The right hand switch had all of the wires disconnected from it except for the starter button. The wires to the RUN switch were cut and soldered together leaving the run switch obsolete. The headlight ON/OFF switch was also cut and the wires soldered together making the headlight always on.
After disassembling and cleaning the switch (read the excellent tutorial by SohRon) I soldered new wires, tested with my meter and reassembled/reinstalled the switch. Works great! Now I can turn my headlights on and off at will as well as having a functional RUN switch! Now for the fun part. Since I was installing new bars, I had to remove the old wiring running inside the old bars for the left switch. (lubricate thoroughly before you start) Pulling them out was a real bear, and I was not about to even try to run the wires in the new bar. So, I had to modify the switch so that the wires could be run on the outside. After pulling the switch apart and re-routing the wires, I took a carbide dremel bit, and hollowed out a "U" shape on the bottom half of the switch facing the clutch lever. (but far enough to one side so as not to affect travel. Reinstalled, tested clutch travel, tested switch functions...WORKING! I plan to install a small rubber grommet at the hole opening just to be safe. I did use a polishing wheel to round and smooth the edges, but ya never can be too careful. Anyone else tried this?
