I replaced the gears years ago with bronze and the delrin bushings. I cant believe I need to do it again.
When I turn the lights on, the drivers side only goes half way and the knob on top is spinning pretty darn fast. Once it stops, I turn it to get the light all the way up.

Bushings are shot. I've read not to use the bronze gear, though, due to extra weight and it chews things up faster. I'm not sure if that's an internet rumor or not.

Sucks about having to do the job again

its not really a tough job. just a pain

I am wondering if I can just pull the roll pin, then the cover where the gears are. Seems like we take allot off to get to the gears when they are under the cover/gear, which has three bolts and the roll pin keeping the shaft in.
http://home.comcast.net/~zrjuan/headlight.html

Well, here is my bushing. They all are the right size and in great shape. The bronze gear had a few pieces(very) of old bushing or dirt on the gears, but was clean otherwise.
[IMG]http://i280.photobucket.com/albums/kk189/rivary0006/bushing2.jpg[/IMG]
Thats a 7/16 wrench to show it meets the correct size of less than .465.

Strange. I wonder if the debris was making the motor think it hit the limiter.

Did you end up removing the whole assembly? I don't see you being able to get the cover off without removing it?

Matthew

I took everything apart. Nothing damaged, or stripped. I then turned the motor by hand using the knob. Everything turned fine. The only thing that can strip is the metal rod that goes through the brass gear, as it has teeth on it to. But its fine and so is the brass gear, and it went on tight. I put a little loctite for shits and giggles on the rod.

The only other thing I could think it would be is the external linkage. I accidentally bent one of the washers and it provided enough resistance the headlight wouldn't go up.

Matthew