Start switch melted.

[Grandpa Bigbuck]

My wife has a 2001 standard with motor trike conversion. Yesterday we were out for a ride when I noticed she had no headlight. Found the start switch melted. 2nd one in 2 years. I know there is a modification that involves adding a relay to the headlight circuit, but what exactly is causing the switch to melt? I also have a 2001 and have not experienced any of these issues.

[BonS]

Are you running a standard wattage headlight? Any extra running lights? Excess current draw can do it so a relay must be added if you amp-up the headlights. Of course, another possibility is simply that the switch is bad and has high contact resistance which causes heat and melting. Bummer.

[BobB]

With standard OEM wiring, the entire amperage for the headlamp goes through the starter switch.  That power is then routed to the hi/low beam switch on the left handlebar.  That switch can fail in the same way.  Are you using a head lamp bulb that is a higher wattage than normal?  If so, you will be even more prone to switch failures.  I highly recommend the modification to protect both switches.  I did mine two  years ago and have had no further switch issues.

Here is the write up that I did at that time.
http://www.valkyrieforum.com/bbs/index.php/topic,55747.msg535635.html#msg535635

[Grandpa Bigbuck]

Would installing a LED bulb that is rated at 20/40 watts eliminate this problem?

[BonS]

Well, it sure should.

I just helped out a friend this weekend with the same issue. The switch was too melted to salvage. He has a Tourer with a stock bulb, low miles, no extra lights. The copper contact in the switch wasn't burned but there must be a lot of electrical resistance at the contacts so I assume that the lubrication had dried out and the internal brass contact couldn't move freely to make a good contact. The result is heat, melting and toast.