Right here goes.
Here is evrything you need for the job
1. Socket Set
2. Pan to catch coolant
3. 1 litre of coolant concetrate
4. Funnel and lenght of hose
5. Normal Grease
6. Dielectric Grease
7. ACF-50
8. Emery Board (disposable nail file)
9. Phillips screwdriver
10. Very small flat head screwdriver
First off you need to establish why your headlight isn't working. Wiggle the wires that come down from the starter switch at the point where they disappear behind the radiator. If this causes the light to come on or off them chances are it is the connector that is behind the radiator that is at fault.
If not then it could still be the connector but I would start with the starter switch fault (link on here somewhere) as it is the easiest to fix.
1. You must remove the side pannels of the wee. (see dr Vstrom tank removel video on You tube)
2. Then you will need to drain the coolant out of the system (see dr Vstrom video for coolant change)
3. First remove the 3 hoses connected to the radiator. Place a towl over the front mud guard to protect it form scratching. Once this is done remove the bottom bolt show in the picture.
Remove the radiator protector if you have one.
Loosen the top bolt arrowed in the picture and pivot the radiator forward. This will give you slightly better access. Disconnect the white fan connector ( see picture)
Also disconnect the 2 connectors on the horn.
Now remove the top bolt on the radiator and move maneuver it away from the bike.
There are 2 clips on the top of the plastic shield (see picture)
Unclip these and the radiator should come completely away from the bike leaving the sheild held in place by the wiring.
Push all the connector clips through and the plastic shield should come away as well leaving you this (see picture).
Uncouple all the connectors and give both the female and male side a squirt of ACF-50 and leave to soak.
Once they have soaked for a while use the emery board to file the male connectors and get rid of any corrosion.
Then clean out any residual crud left in the male connectors.
Reconnect the connecters and see if everything works.
In my case this did'nt do the trick so using the small screwdriver I removed the 2 headlight female pins out of the connector(large black connector block the 2 largest wires on the left of the block.)
This is easiest done with 2 people. The female connectors are held in place by a plastic retaining clip inside the block. Place the flat head srewdriver below the connector and prize the retaining clip downwards, have a buddy then pull the connector out of the block with a pair of long nosed pliers. If by yourself this is a total pain in the a*s*.
The connector could just need reshaping or just a good clean.
Then reconnect and see if the headlight works.
If it does then open up the plug and put a small splodge of Dielectic grease in. This just prevents water from getting in and prevents Corrosion.
Connect the plug and recheck if it works. If it isn't working then it is likely that the grease is forming a barrier and you may need to reshape the female connecter.
If it works give the plug an thorough wiggle making sure the headlight doesn't flicker.
If it still works you can put everything back together. The only thing to do differntly is to connect the plastic shield to the back of the radiator before putting it back on the bike.
For refilling the coolant follow the Dr Vstrom video but if you use a short length of hose with a funnel you can refill the coolant bottle without having to completely remove the tank.
Also always grease any bolts when putting them back (copper grease on the lower rad bolt if you've got it)
Good luck
