So I was gonna get my new meter out and try to start learning how to use it testing on the headlight switch wiring as suggested by Drew-py. I thought let me take one more look at the wiring before I go at it. I saw the fusible link wires in the loom in the front but never pulled them out to check on the link because the headlights actually worked, I just had to half press the switch.
Well when I pulled out the wires I found a surprise from the previous owner. The fusible link is gone and the pink wires are silver ducked taped and elec taped together to the red wire?
Not sure what it means for the half press? I figure the wiring is correct because the headlights work as they should less the switch half press.
I even took apart the actual switch and is is really basic with no obvious reason to not work. It only has (3) positions where the copper tangs contact the base and complete what I assume is the circuit. Here is an image from a pennocks post:
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Below is a link to the article with an exert. It is about a gen 2 system but I think the switch wiring is the same.
"Once the rocker removed, you'll see three prongs.
When the lights are down, only prong #3 makes contact with the base plate
When the marker/tail lights only are on, only prong #2 makes contact with the base plate
When all lights are on, only prong #1 and #2 make contact with the base plate."
When apart what is curious is that the half press makes all the 3 prongs contact the base plate? When the lights get to fully up and I let go of the switch just prongs 1 & 2 are making contact? Is it possible that full contact of all 3 prongs makes a connection happen that is supposed to be happening another way somewhere else and in a different way? (In normal operating action prong 3 raised off the base plate as prongs 1&2 connect)
So at this point I guess for safety I should redo the fusible link? Not sure that will fix the half press issue.