Headlight Doesn't Work - 1 Year Old PDM

Energy One
AZ Rider

AZ Rider

Member
I just bought my first BD today. A 2005 Bulldog. Everything checked out when I took the bike for a test ride. But, soon after the purchase I noticed the tach on the Dakota Digital wasn't working. Parked the bike turned it off and back on and the tach worked and has ever since. Throughout all of this the headlight was on. I have a habit of checking my lights in the reflection of the vehicle in front of me at stops, so I know it was working throughout the day.

As I rode home tonight I noticed the headlight wasn't on. By this point it was getting dark and there was no question it wasn't on. 10 more minutes of riding on roads without street lights was not how I planned my evening. Was just hoping I wouldn't get ran over.

Anyway, I took apart the headlight assembly and the bulb looked good, but I still went and purchased another. It still doesn't work.

So, my questions are:

1 - Does this sound like a bad PDM (it only has about 1,500 miles on it)? I haven't seen a lot of posts of issues with the new PDMs after replacing the EHCs.

2 - If not the PDM what could it be?

3 - What are my options to troubleshoot? Check voltage at the connector?

NEW Question
4 - Am I correct in assuming that since the headlight and starter solenoid are on the same fuse and relay that if either the fuse or relay had an issue the bike wouldn't start either? FYI - I did check all the fuses just to be safe and they are all good.

I've searched through the site and didn't find this specific issue in regards to the PDM and headlight, but perhaps I missed something. Any help would be greatly appreciated.
 
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francoblay1

francoblay1

The Spaniard
Definitely check for voltage at the connector, then make your way down checking for bad wires/shorts

I would not think the problem is in the controls... but it could also be it.

Since you have it opened up, I would replace it with a ceramic one, the plastic ones are known for "melting" with the heat. and apply dielectric grease on all connections.

Keep us posted on your findings.
 
HMAN

HMAN

I just like my Freedom
Supporting Member
Check ur keyswitch, and look for shorts under the tank. Jm .02
 
HMAN

HMAN

I just like my Freedom
Supporting Member
Just make sure it is making full connection. You stated the tach wasnt working until you cycled the keyswitch. BD switches have been known to act up. And like Franco suggested, check the headlight plug for power. Bet its something fairly simple. Folks tend to always look for the complicated when most of time its simple. Good luck n keep us posted. You will get this figured out......eventually lol.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
francoblay1 said:
Definitely check for voltage at the connector, then make your way down checking for bad wires/shorts

I would not think the problem is in the controls... but it could also be it.

Since you have it opened up, I would replace it with a ceramic one, the plastic ones are known for "melting" with the heat. and apply dielectric grease on all connections.

Keep us posted on your findings.
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Did you do what Franco said yet? I hope you have a volt-meter? If not do yourself a big favor and go buy one. You should have 12v when the key is turned on the connector that mates to the yellow wire (low beam) against the black ground wire. Bike does not have to be running. The White wire is for your high beam and should only have 12v when switched to high beam.

This will be step 1. But basically you will have to work your way backwards if you don't have power there. It's very likely that if it's not in the headlight bucket then it could be a wire rubbed bare under the gas tank. While you are looking at the headlight check to make sure the connector isn't melted the stock ones were plastic which melt.

Regarding your tach issue, that happens quite frequently turn on the key and start the bike without letting the tach cycle prior starting. If it was on and shut off while riding however that is a different problem and could be the keyswitch but I would expect bike to die as well.
 
Brew

Brew

Troop Supporter
I didn't see any mention about the fuse. Might not be it, but there's always a that chance.
 
AZ Rider

AZ Rider

Member
Brew said:
I didn't see any mention about the fuse. Might not be it, but there's always a that chance.
Click to expand...
Yes, I did check the fuses and everything was good.

Ordered a voltmeter from [ame=http://www.amazon.com/gp/product/B000EVYGZA/ref=od_aui_detailpages00?ie=UTF8&psc=1#productDetails]Amazon[/ame] that will be here today, so I can check the voltage.

Now the damn air ride adjustment doesn't work. Two issues in 2 days of owning the bike. Not exactly the way I was hoping things would go. But, hey it's only a motorcycle, I'll get it figured out. Or pay someone to :rolleyes: .
 
AZ Rider

AZ Rider

Member
Th3InfamousI said:
Did you do what Franco said yet? I hope you have a volt-meter? If not do yourself a big favor and go buy one. You should have 12v when the key is turned on the connector that mates to the yellow wire (low beam) against the black ground wire. Bike does not have to be running. The White wire is for your high beam and should only have 12v when switched to high beam.

This will be step 1. But basically you will have to work your way backwards if you don't have power there. It's very likely that if it's not in the headlight bucket then it could be a wire rubbed bare under the gas tank. While you are looking at the headlight check to make sure the connector isn't melted the stock ones were plastic which melt.

Regarding your tach issue, that happens quite frequently turn on the key and start the bike without letting the tach cycle prior starting. If it was on and shut off while riding however that is a different problem and could be the keyswitch but I would expect bike to die as well.
Click to expand...
There is no power to the connector and the connector is in perfect shape. I guess that means I need to take off the gas tank and check the wires there?
 
AZ Rider

AZ Rider

Member
That air ride is hooked up to a separate fused toggle switch. The fuse was blown. New fuse and it works fine. Now to figure out this headlight. :bang:
 
AZ Rider

AZ Rider

Member
Got the tank off and there is not any wear on the wires. I disconnected the plugs under the tank to the headlight and checked those. No juice. I disconnected the plug to the left hand controls. Got juice to the horn and turn signal, but no juice to the high/low beam button. I also swapped relays just to check if that may be bad and that didn't have any effect.

Any ideas?
 
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KaptinAmerika

KaptinAmerika

Guru
Check the input and output at the HCI for the headlight circuit. That will clear the issue up pretty quick for you.

You might get lucky and find a replacement HCI somewhere but I kind of doubt it.

Replace the PDM kit with another setup.
 
AZ Rider

AZ Rider

Member
KaptinAmerika said:
Check the input and output at the HCI for the headlight circuit. That will clear the issue up pretty quick for you.

You might get lucky and find a replacement HCI somewhere but I kind of doubt it.

Replace the PDM kit with another setup.
Click to expand...
Hell I can't get those damn plugs without getting all the air ride crap out of the way... For the love...
 
AZ Rider

AZ Rider

Member
It's possible to wire the headlight around the HCI isn't it? If that is the issue, I'm not sure I want to keep dealing with this unit.
 
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