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Re: Headlight Dimmer Switch
Posted by Chris Ault (more from Chris Ault) on Fri, 24 Nov 2000 19:52:34
In Reply to: , Kok Chen, Sat, 17 Dec 1988 12:00:00

I had that with my 87 9000 T last year. No high beams.

That little plastic square 'wheel' inside the switch melts and becomes
circular preventing the reed switch from tripping the high beams. Wonderfiul
design, that. Common problem.

I tried rebuilding the wheel with reson epoxy. Lasted a day.

Then I tried a plastic epoxy in a tube, can't remember the name but it is
till working today. Goes on thick, you can shape it roughly while it's wet,
then dries very hard. Rebuild the shape of that wheel, sand it down to
square and you're off. Very little effort.

Another problem I've noticed is that the headlights intermittently shut off
- loose connection at the back of the signal switch cluster. There's a lot
of current flowing through that plastic and it tends to melt, causing the
connection (for the headlights) to widen and be compromised. I put a small
bead of solder onto the spade (making it thicker) which made a positive
connection. (this is on the upper of the three connectors, when the switch
cluster is installed). No problem since.

A couple of $0.05 solutions to a $150 problem.

Good luck.

-chris
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