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Headlight Switch Modification (for extra position and cutoff)

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Not sure if this is normal for these bikes, but on my '09 SM, the stock low beam is basically a trail headlight. Doesn't have anywhere near the range necessary for road use, even aimed properly. The high beam, however, works quite well.

I thought it might be possible to modify the existing switch to have more functions, and was successful this morning. My stock switch now has four positions. Bottom to top, there is off, low, both low and high, high. Made a position to run low and high together as a way to flash from high beam to even brighter. I don't plan on running it long in that position as I figure it might create a lot of head and possibly cause premature failure of the bulb or wiring.

I basically took the thing apart, made some new notches where the ball rides, cut some off the edges so the switch moves through more degrees of travel, and covered half of the low beam contact with 2 part quick set epoxy.

I made the two new notches smaller than the two original, so it's a little harder to put the switch there and easy to find regular low and high.

Here are a bunch of pictures I took, and I could add some more write up if anyone's interested.

ImageUploadedByThumper Talk1408033089.897424.jpgImageUploadedByThumper Talk1408033108.179686.jpgImageUploadedByThumper Talk1408033128.162844.jpgImageUploadedByThumper Talk1408033147.897370.jpgImageUploadedByThumper Talk1408033162.562643.jpgImageUploadedByThumper Talk1408033196.898199.jpgImageUploadedByThumper Talk1408033205.396707.jpgImageUploadedByThumper Talk1408033217.745956.jpgImageUploadedByThumper Talk1408033233.279842.jpgImageUploadedByThumper Talk1408033244.713549.jpgImageUploadedByThumper Talk1408033257.147432.jpgImageUploadedByThumper Talk1408033265.797350.jpg

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Interesting! I'm playing with that part of the harness as well except I'm deleting mine ;) I don't have TS, Horn, and I have an custom headlight setup so I'm going to through a hide - a - switch in my bar pad for high! Just need to get the connectors and wire it up tm night! Cool idea though on yours! I really like the Off feature!

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