[Dave at Pelican Parts]

Do you have to lower the headlight manually, or just raise it manually? If it will lower on its own when you turn the lights off, then I would suspect one of the microswitches in the headlight lifting assembly.

Check the wires that go to the headlight assembly as well. There should be a grey wire and a green/black (green with a black tracer stripe) wire. I believe the green/black one carries the "put the light down" signal, and it should be getting +12V when the key is on and the headlight switch is closed. (Double-check me with the side that actually works correctly.) The grey one should carry the "raise the headlights" signal, and get +12V when the key is on and the headlight switch is pulled out.

There should be a red wire going to the relay that is always hot, a green wire that actually sends power to the motor when appropriate, a black wire that connects to the microswitch/cam assembly in the headlight linkage, and a brown wire that is permanently grounded.

Check that the relay pins are getting the appropriate power and ground as well.

--DD