2002 Insight headlight switch failure and repair.

[mikep_95133]

Back in August my headlight switch died as they so often do. So looking through our forum I found some owners had replaced the switch more than once.

I used the Honda Service Bulletin 04-015 to look up the part number of the switch. The bulletin had the headlight switch kit p/n listed (35012-S3Y-306), that is used for the recall. The kit comes with a connector and one pin with a red/white wire crimped on, and the switch. The funny thing was the kit price was far cheaper than the switch by itself. Even the parts guy was surprised.

Since the replacement switch was not improved and keeps failing, I am going to add a Bosch relay to handle the load instead of the switch. The coil on the relay is about 90 ohms generally and so the load will be far less than the headlights themselves. Bosch relays are $5-$10USD.

When I get done rebuilding this pile of motor controllers I will install the new headlight switch and relay, and post it here and on my blog.

Honda Insight Repair and Upgrade Blog by Mike

Mike

[mikep_95133]

I fixed the Insight headlight switch, but I did not add a relay. After looking at the crimp and wire that were damaged, it was easy to see that they were over heated. Not a surprise since the plastic around the pin in the headlight switch were melted. Here is a pic of the damaged crimp and wire after removal from the Insight wiring harness. This pic shows that the copper wire discolored from over heating. It's very easy to see with the naked eye. Not sure if the pic shows it well enough. But the insulation is definitely darker nearest to the crimp end of the wire. The copper wire discolors and the connection to the crimp gets worse.

http://rotordesign.com/insight/headl...h/P1010248.jpg

Here is what I thought would help keep the connection in better condition as it ages. I soldered it. This will take out the ability of the wire to affect the connection. We'll see how long it lasts.

http://rotordesign.com/insight/headl...h/P1010238.jpg

Mike