Motoscrubs.com

I am working on a 1967 250 Scrambler. I am having problems getting the Headlight/Dimmer switch wired correctly. I do have all the schematic drawings, but they are a bit vague as to the exact location of the different wires. The 2 white ones for the headlight beam are simple.
Does anyone have a picture of the switch opened up, showing the the wire colors and locations?
Mine is a handlebar mount and has the 3 positions: 1 - 0 - 2. What are the uses of these positions? Even that will help me.

According to narrow case owners' manual, the switch action is different according to whether the ignition key is inserted or not.
With key in, 0 is all OFF, 1 is park lights ON, 2 is headlight ON.
With key not in, the same except you can't turn on the headlight.

I strongly suggest that you consider using relays in the lighting circuits.
Otherwise, you are very likely to experience trouble with the frankly inadequate switchgear, especially the headlight dip switch.
They are not durable in the long term, which was sort of OK when they were pocket money to buy, but that's not the case any more.
If you are interested I'll provide a wiring diagram for a relay modification.
I believe our list owner also has some knowledge on this topic, and may be able to provide an off the shelf solution.
With relays, you can keep the original switches as they will be relieved of the heavy duty electrical duties.
And there's no need then to resort to horrid looking modern switches.

Check this out for a neat relay solution:

http://culayer.com/product/matchbox-headlight-relay/

Available for 6V and 12V systems.

Unfortunately all out of stock ...

You can still use standard automotive relays, available in 6V if you look hard enough.
You can use only one to protect the dip switch only, or two for lights on/off as well.