Each and nearly every time I turn on my AFM and start play the same roll over switch at the top of the playfield will not register until it has been rolled over 4 - 5 times, after which it will work reliably until the game is turned off.

Its a switch function issue (the bulb always works if the other lane is lit and you swap the light to that lane by pushing a flipper) - not a bulb issue.

I reshaped the switch several times, then finally replaced it, but the behavior has not changed. Suspect this is mechanical in nature, but I can't explain why it takes a few activations for it to start working. Gives the game a certain personality I guess.

This behavior is so consistent, about 3 - 4 minutes into ball one (assuming I did not have the first ball drain quickly) it will start working and not fail to register again during that game or subsequent games. If I leave the game on and walk away for a few hours when I start the next game it works immediately.

Good suggestion. I will try it later tonight

I have already replaced the switch, thanks.