Headlight Problem, but something different...

Shaunmac

Shaunmac

How YOU doin?
Hi everyone,

I just got my new (to me) 2005 Chopper two days ago. Last night I was cruising around, stopped at a buddy of mine's work to show it off, everything was great. And then...

As I was getting ready to head out, I turned the key, and no light. The bright indicator was on, but no light. Switching between brights and lows did nothing. I ended up driving home with no light on a pitch black road with other cars flashing their brights at me the whole time. Not fun.

This morning I went out to have a look after reading through this forum about light issues. I thought that the bulb was out and decided to double check it one last time. I turned the key, and the light was on. Needless to say, it wasn't the bulb.

Any ideas what the hell is going on here? I'm really skeptical about going out at night now not knowing what's going on here, and I'm supposed to be going riding tomorrow night to go meet some people out.

Please help!!!
Shaun
 
Raywood

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
Check for a grounded wire under the tank. Wiring is very tight under there and apt to grounds. When it gets hot things swell and end up grounding.

:cheers:
 
jimizee028

jimizee028

TRUE COLORS COLLISION
double checkalso the the plastic socket that the bulbs 3 prongs slip into and make sure its still good and not melted up...
 
avdhunter

avdhunter

Active Member
Do as mentioned above!!!:2thumbs: Then also bring a real good flashlight and some tape with ya....:cheers: J/K let us know what ya find.
 
Daddycool

Daddycool

Active Member
there was a service bulletin a few years back about the plug inside the headlight housing melting. Call your dealer or BDM and give them your VIN. They should be able to tell you if it has been done already.

I know this cause mine melted.
 
BigB

BigB

Member
I am having the same problem yesterday with an 04 Chopper. Checked the headlight plug, the plug under the tank, the hi low switch connection, nothing made a difference. I got up today turned on the key and had low beam, no high beam. Turned the key on and off a few times and no light at all again. I checked the bulb and both beams work. I was wondering if it could be the EHC? I'll let you know if I find something. If any one else knows a fix please post.

Big B
 
Slider

Slider

Active Member
Put in a new bulb, they are cheap, just make sure it's 55/60w and not higher, EHC can't handle higher wattages, neither can the connector in the bucket. Any other elctrical problems like tach light flashing, speedo needle acting up, backfiring? I had the low/ high beam issues first then eventually, things got worse, needed a new EHC. Rule out evrything else first though, including battery connections, check for the obvious first, get to know your bike- you'll need it later on.
 
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f-okie

f-okie

AllGaveSome-SomeGaveAll
I had the same problem while on a road trip to Salt Lake City---it was the ground wire in the headlight housing-it broke.:flag:
 
Shaunmac

Shaunmac

How YOU doin?
Ok, I pulled off the headlight, and sure enough, it appeared that the housing melted a little bit. It was on the side of the ground wire, (which was also loose, which is more than likely why the light was intermittent) so I pulled it apart, broke away the burnt up plastic, then plugged the wire back in and the light came right on.

Here's the problem. Now ONLY the high beams work. Low beams no longer work at all. I don't think it's the bulb because it just worked earlier today.

I'm guessing you guys are going to tell me to get a new plug, I just don't want to have to wait to ride this thing till one comes in! I want to go ride NOW!

Any other ideas?
 
Shaunmac

Shaunmac

How YOU doin?
Never mind... I just pulled open the headlight again and double checked it. Somehow between the time that I started this project tonight and now, I managed to blow the low beam in the headlight. I know because I can see the little spring rolling around inside of it. Looks like I'll need to get a new one tomorrow.

Is this something that I can only get at Big Dog? Or is this something that an auto zone or Harley shop would carry? Any ideas?
 
C

crazyjoe

Member
BigB I have 04 pitbull. My headlight went out, after checking everything I ended up with new ehc. Now everthing is fine.
 
aspen874

aspen874

Well-Known Member
Supporting Member
call tim or ryan at BD Gateway, they may have the part in stock
ph 314-291-6333

Aspen
 
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