I find that my low beam/high beam are not functioning. The high beam flash is ok. I've taken apart the switch (as per the download section) and if I jump the contacts, I get light, so obviously in the switch. I've cleaned up the contact on both parts of the switch but still no joy. Wondering if the power (green wire) contact has worn down too low? How could I build it back up? A little solder? Options?

The power for the Hi beam flash comes from a different source than the regular Hi/Lo.
The white/Yellow wire comes from the right hand switch block so check that the power is getting to that at the left block. There is also a powered wire Green/Blue that powers the flash function. Make sure you are testing from the correct wire first.
Usually when the Hi/Lo fail it is due to the White/Yellow wire not getting power from the right switch block.

aye ! look on the output of the right hand side cables

Thanks lads, I have power at the yellow/wht wire and blue/green wire.

Your right switch block is OK
Check that there is earth on the brown wire at the 3 pin plug on the headlight.
You can put a dob of solder on the contacts to make them work better but care is required as the plastic can melt so use a very hot iron to get heat in quickly and cool with water immediately. Doing a small bit at a time is best.
Best of luck

So I have a ground at the headlight plug and continuity in the wiring between the left switch and the plug. No power to the yellow wire at the plug, no power to the white wire at the plug unless I use the high beam flash function. What am I missing????

It has to be the contacts that aren't making contact in the left switch

Hi mate it probably won't apply to your bike but mine is an ex police machine and I had the same trouble. I had to follow the yellow wire back from the switchgear down the handlebars to where I found they had just spliced
the yellow/green together when they removed the police flashing thingos, they just taped them together. It took me ages to figure it out, I almost lost my hair. The flasher and high beam worked but not the headlight.
RT

Alright, all fixed. The yellow/white wire inner contact (inside the switch) was low, worn I guess. A little dab of solder to bring it back up and I'm back in business. Thanks for the efforts lads.

good work clubbie ....

i would be looking far a new mechanism ....solder isnt the best thing for wear ...

i hope you have installed the relays for the headlamp ...as this would give the switch a better chance at surviving (lower currents )

charlie99 wrote: good work clubbie ....

+1

charlie99 wrote:i would be looking far a new mechanism ....solder isnt the best thing for wear ...

Solder is soft, but the switch contacts don`t get much worn I think.
Repaired a lot of these switches with this metod...and at all of them the y/w contact have been spark eroded and because of that being below surface.

Have also done this work on my RS ~20 years ago, the switch still functions.

charlie99 wrote:i hope you have installed the relays for the headlamp ...as this would give the switch a better chance at surviving (lower currents )

+1. Relays is a must, after a repair like this.