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Discussion Starter #1
Gentlemen (and ladies)

Been struggling with the "headlights out" problem for months now. Installed the EB relay kit, only to realize the damage had been done in the handlebar (starter) switch. So I ordered a new one.

Got the bike stripped of the fairings, tank and air filter in preperation for the new install. But I am having a problem removing the wiring harness that runs up to the starter switch, the black one that sits to the right, behind the radiator. Just can't seem to find a good way in there to disconnect the harness. It looks like if the whole air cleaner assembly came out you could get a few hands in there, but otherwise I dunno.

Any advice here fellas?

-long time lurker, first time poster-
 

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You could probably repair the existing switch and save yourself the replacement. To do that I would have directed you here, but it seems that page no longer exists.

Admins ???
 

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The Black Lab starter switch story is now at Start Switch Maintenance « Black Lab Adventures

The connector from the switch wiring harness is pinned to the radiator shroud. Loosening the radiator for better access may be the way to go.
 

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Discussion Starter #5
Why is the stromtrooper.com link missing.
Thats what I was wondering too. Thanks guys, the damage is done and a new switch will be here next week, just having some wrist/arm contortions trying to get this thing unplugged.
 

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Why is the stromtrooper.com link missing.
I'm pretty sure Black Lab is putting his how-to posts in his own web site and taking them down here.
 

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Discussion Starter #9
Thanks, removing the harness from the cowling definitely made it easier to disconnect. Quite a pain in the arse.

Well, got the fairings and tank off and prepping them for paint. Waiting for the new switch via USPS. Anything else I should do in here while she's bare? Topping off coolant, replacing air filter...she's only got 17K on 'er.
 

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FORUM GODFATHER.....R.I.P. PAT
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His wasn't the only useful post there. Where are the others.
I don't remember any other starter switch how-tos. That being said, a Google search on starter switch maintenance finds:

http://www.stromtrooper.com/v-strom...-exploded-view-starter-switch-2004-dl650.html
http://www.stromtrooper.com/maintenance-tech-farkles/49334-starter-switch-maintenance.html

and Black Lab's http://www.stromtrooper.com/maintenance-how/44177-start-switch-maintenance-pics.html but his pics have been removed. There are also a bunch of headlight out threads with starter switch issues.
 

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Discussion Starter #11
I don't remember any other starter switch how-tos. That being said, a Google search on starter switch maintenance finds:

http://www.stromtrooper.com/v-strom...-exploded-view-starter-switch-2004-dl650.html
http://www.stromtrooper.com/maintenance-tech-farkles/49334-starter-switch-maintenance.html

and Black Lab's http://www.stromtrooper.com/maintenance-how/44177-start-switch-maintenance-pics.html but his pics have been removed. There are also a bunch of headlight out threads with starter switch issues.
Yep, I've googled, yelped, yahooed and binged this topic to death, and both threads you've linked to eventually just lead to an invalid thread message. Hence the post.

Now I'm just looking at the bike stripped down in my living room, pondering on what I can do to it during the next week or so while I wait for the new switch. Southern Colorado is expecting temps in the mid-50's next week which will be perfect for touching up my killer DIY paint job. I've had Strom riders come up and ask me what bike I'm riding :beatnik:
 

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They are alive now.
 

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Make sure you use a good coating of dielectric grease on the connector before putting it back together. Alot of water and grime can get pumped into the contact especially in that area and the dielectric grease may prevent future problems.
 

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All I get is this.
Maybe it's because admins got tired of my reporting spammers and oil threads so recently gave me the tools to handle them myself.
 

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I got some moderator tools a couple of days ago. I can nuke spammers and move oil posts to the big oil thread for example.
 
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