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Thought I'd throw this one in the club section to help raise the lack of activity here. I'm fixing up a '00 Bayou 220 that I picked up last weekend; needs the carb rebuilt, at least that's all I was hoping it needed. Anyways, decided to check the battery, starter, spark, all that jazz so I was good to go when I got the carb fixed.. and that's when I found an intermittent short in the start switch as well as the headlight switch. So I removed the switch housing from the handlebar to find this:

20181125_141415s.jpg.22e77529245160af26eb05984eb3514b.jpg

I dismantled the entire assembly, blew it all out with compressed air, cleaned everything including the corroded contacts, and then reassembled it all making sure to put dielectric grease on all the exposed electrical. It looks 1000x better than before and everything works as it should (though I think I installed the kill switch backwards lol). 

My question is this: Is that good enough? As a former auto mechanic, I'd always seal any external electronics to prevent dirt, moisture, etc from getting in. However, the design of the housing doesn't really make this possible. I'm not trying to make this thing 100% submersible, but with the switch being old/original I'd like to know it won't fail on me if I get caught in a downpour or something.

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      1986   Scrambler
      1986   Trail Boss
      1986   Scrambler
      1986   Trail Boss
      1987   Trail Boss
      1987   Cyclone
      1987   Trail Boss 4x4
      1987   Trail Boss 4x4
      1987   Trail Boss 4x4
      1988   Trail Boss 2x4
      1988   Trail Boss 4x4
      1988   Trail Boss 250 RIES
      1988   Trail Boss 250 RIES
      1989   Trail Boss
      1989   Trail Boss 2x4
      1989   Trail Boss 4x4
      1989   Big Boss 4x6
      1989   Big Boss 4x6
      1990   Trail Blazer
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      1990   Trail Boss 2x4
      1990   Trail Boss 2x4 350L
      1990   Trail Boss 4x4
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      1990   Big Boss 4x6
      1991   Trail Blazer
      1991   Trail Boss 250
      1991   Trail Boss 2x4
      1991   Trail Boss 2x4 350L
      1991   Trail Boss 4x4
      1991   Trail Boss 4x4 350L
      1991   Big Boss 4x6
      1991   Big Boss 6x6
      1992   Trail Blazer
      1992   Trail Boss 250
      1992   Trail Boss 2x4
      1992   Trail Boss 2x4 350L
      1992   Trail Boss 4x4
      1992   Trail Boss 4x4 350L
      1992   Big Boss 4x6
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      1993   2502x4
      1993   3502x4
      1993   2504x4
      1993   3504x4
      1993   Sportsman
      1993   2506x6
      1993   3506x6
      1993   Trail Boss
      1993   Trail Blazer
      1994   3002x4
      1994   4002x4
      1994   3004x4
      1994   4004x4
      1994   3006x6
      1994   4006x6
      1994   Trail Boss 2W
      1994   Trail Blazer 2W
      1994   Sportsman 4x4
      1994   Sport
      1995   3002x4
      1995   4002x4
      1995   3004x4
      1995   Xplorer4x4
      1995   4006x6
      1995   Trail Boss
      1995   Trail Blazer
      1995   Sportsman 4x4
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