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Old 05-11-2013, 03:22 PM   #1
Echolake OP
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Joined: Oct 2012
Location: Snohomish, WA
Oddometer: 6
Bluhduh '72 R75/5-How to remove Ignition switch and terminal board inside headlight Bucket?

OK, I give up. Does anyone know the secret to removing the terminal board inside the headlight? I have searched this forum and every manual I can find. I am at a complete loss....
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Old 05-11-2013, 04:19 PM   #2
Plaka
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Quote:
Originally Posted by Echolake View Post
OK, I give up. Does anyone know the secret to removing the terminal board inside the headlight? I have searched this forum and every manual I can find. I am at a complete loss....
Yeah...don't.

It is held in by folded metal tabs on the inside. unfold the tabs and they break when you try to re-use them, .

Plaka screwed with this post 05-11-2013 at 04:26 PM
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Old 05-11-2013, 05:01 PM   #3
JonnyCash
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I've done it twice on mine over the 20 years I've had it, and I'm sure I could never get away with a third time. If I ever have to take it out again, I'll need to come up with another way to hold it in there, maybe weld some other tabs. My headlight switch is a little funky, but I'm going to live with it until it just won't work any more before I pull it apart.
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Old 05-11-2013, 05:31 PM   #4
Echolake OP
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Thanks

Thanks for the replies...I took a chance and unbent 'em. Fingers crossed when I reassemble.
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Old 05-11-2013, 05:49 PM   #5
Kanticoy
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Joined: May 2013
Location: Birmingham, AL
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I just did that since the original switch in mine just spun with no purchase. I replaced it with the aftermarket switch from Rocky Point. Much happier with it and couldn't be easier to install.
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Old 05-11-2013, 06:13 PM   #6
Bill Harris
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Location: backwoods Alabama
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Quote:
Originally Posted by JonnyCash View Post
I've done it twice on mine over the 20 years I've had it, and I'm sure I could never get away with a third time. If I ever have to take it out again, I'll need to come up with another way to hold it in there, maybe weld some other tabs. My headlight switch is a little funky, but I'm going to live with it until it just won't work any more before I pull it apart.
I'm on my third removal in 40 years-- I think that next time will be _it_. I'm toying around with the idea of making a thin metal sleeve to fit inside the one in the headlight bucket that will have small screws to attach the switch board with.

--Bill
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Old 05-11-2013, 06:26 PM   #7
Chad M
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Those tabs can be annealed to remove the work hardening done by the twisting motion. I've heard of guys using a 12v battery to localize the heat.
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Old 05-11-2013, 08:21 PM   #8
spo123
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Cool2 Bingo!

First prize for Chad M!
HOWEVER> DO NOT remove that board assembly unless ABSOLUTELY necessary.
Ensure good, clean connections from underneath and use a clean and non residue forming ELECTRICAL cleaner....Sometimes the ARM needs to be REFORMED (bent) slightly for proper contact....Sometimes the POINTS are burned and need to be BURNISHED.....Yes, POINTS.
You will see.
Troubleshoot everything up to the SWITCH BOARD first.
Good Luck.
In the last 58,000 miles, I have not needed to remove mine...

See 'ya,
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