Rick G
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Number of posts : 12048
At an educated guess I'd say you have a heat induced problem that is caused by the contacts of the hi/lo switch being asked to carry far too much current. It melts the insulation and the plastic block the contacts are in.
You can pull the switches apart, do it inside a clear plastic bag so the small springs etc don't escape.
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"Man sacrifices his health in order to make money.
Then he sacrifices money to recuperate his health.
And then he is so anxious about the future that he does not enjoy the present; the result being that he does not live in the present or the future; he lives as if he is never going to die, and then dies having never really lived." Dalai Lama
Bikes 1999 K1100 LT with a Big Block 1200