'75 L Bug

Headlights would not switch to high beam, no 'clicking' noise when attempting to switch. Checked fuses, all okay. Fitted a new relay, lights would then flick between low and high beam without issue, but, lights could not be switched off. If I turned off the light switch they stayed on low beam. Fitted the old relay, back to the same issue, no high beam.

What next? Try another relay? I hate electricals.

Take a look at this diagram

73>Beetle wiring

E1 is the main light switch and J is the dipped relay.

Now the relay gets it's power from the light switch so with the switch off you should get nothing. Hence first issue is remove the relay and between it's power wire (black/white) and an earth connect a bulb or multimeter. Bulb shouldn't light or multimeter shows 0V. If the bulb lights or meter shows voltage then the switch is buggered.

If thats not the case then I'm not sure how power is staying on.

Do the lights work at all with the old relay, either dipped or main?

That's a US spec wiring diagram, Aus and Euro bugs use a different 5 wire relay with a permanantly live so the high beam flash works.

I would check with a meter make sure the dipper switch is working ok,
It should just have a good ground when you pull the stalk and be comletely open circuit when not pulled.
Sounds like it may be sending a ground all the time which is holding the relay in.

THe points on the dipper switch with age can get a build up on them which can stick the contacts together.

Are you sure that you used the correct relay?

Joel is usually correct..

US-north america spec beetles used different wiring diagrams plus a totally different system with different switches and relays..

LEE

I recently replaced the switch mechanism but it was one of the cheap arse ones so wouldn't be surprised if that's my problem. Where do I source a decent replacement? I'm pretty sure that the replacement relay is correct, it does all the right things ...... except turn off.

DOH!!!!! Sorry linked the wrong diagram. This is the right one

73> Euro bugs wiring

The relay still works similarly tho. it's a latching relay but basically means that one of the contacts is always shut so if it's staying on dipped after the lights are switched off then there must still be power coming from the light switch.

The main beam switch would mainly cause issues with the main beam staying on.