Join Date: Jul 2016
Location: San Luis Obispo
Light at the end of the tunnel...
I posted my problem to the Stormtrooper forum last night and got a reply. He didn’t have any direct leads on my problem with the lights, but posted a link to a poll taken among 650 owners. The poll indicated that with the lights out problem, 39% of the time it was traced to the starter switch. Folks suggested to just “clean” the switch contacts and you should be good. This morning I waded into the right-side, split plastic covered mounting piece, two screws, and eventually freed the switch from the housing. Turns out the switch is sealed on this 2015 model, but there are two tiny places where you can spray in some “contact cleaner”, which I didn’t have. What I did do was operate the switch about fifty times in succession, fully depressing it now that it was freed from its housing, with the idea of abrading the internal contact points, and I sprayed a tiny bit of WD 40 into the switch where possible. There are four wires soldered to the top of the sealed switch. Two of the wires showed a very slight browning/tanning at the end of the insulation near the solder dot. All four solder points are very close together. I moved these wires around a bit and reassembled the whole unit. When the starter switch is actuated, contacts move when the button is depressed to opening a circuit to the starter motor and severing the circuit to the headlights. When the engine starts and the button is released back to the default position, the circuit to the headlights is restored. This is the case on the 2015 model.
After trying this approach, I was delighted to find that the headlights worked just as advertised. I'll see how long this lasts under stock wiring conditions. Some posts on the forum have reported very high mileage on the original H-4 headlights as well as no trouble with stock wiring. So I'm hopeful I can ride along relatively care free going forward. Cheers.