02 Bigdog afraid of the dark !

[Dray]

I have a 02 Bigdog that I bought about 7 months ago and I cannot keep a headlight bulb in it. I have replaced the headlight bulb in this bike 6 times now in 7 months. It normally burns out the low beam side first then when i siwtch to the highbeam it will last a couple of days and it is gone as well. I have checked the wiring, mounts everything I can think of, the voltage at the bulb is correct on both circuits. The last time it burnt out it did it when I shut the engine off and it burnt both high and low at the same time. Any ideas? Also I have tried several different brands of bulbs and that doesnt seem to make any difference at all.

Thanks,
Danny

 

[stlmikie]

There is a little trick you can do. I think it involves some wire the same gauge as the headlight wire. You take it and wind it tight around your finger and splice it in on one of the headlight wire in the bucket and that helps with a surge maybe. I have it on my bike but it was done when I got it so? Some one is bound to tell you how to do it correctly none the less. Good luck it should be a pretty easy fix.

 

[bdmridgeback]

Install one of my HID kits and cure your problem. No Filament to burn out any more. If it is a voltage issue from the Voltage Regulator then the ballast will go into protection before it gets damaged.

Otherwise, your bike will take an HID kit with no problems what so ever.

 

[Dray]

Thanks, I'm going to look at your website now. How are these lights as far as vibration goes?

Danny

 

[CCRainman]

Dray check if you have a rubber gasket in the bucket. Vibration causes the bulbs to burn out. I was missing the rubber gasket and I had the same problem as you. Once I put the rubber gaskets in problem solved.

 

[waykool]

Dray check if you have a rubber gasket in the bucket. Vibration causes the bulbs to burn out. I was missing the rubber gasket and I had the same problem as you. Once I put the rubber gaskets in problem solved.

:2thumbs:

 

[stlmikie]

Thing with the hid is that he has the older bucket. If I am not mistaken it is smaller and won't fit. That is why I didn't get one aready.

 

[Dray]

Thanks guys, stlmikie I do have that coil of black wire in the bucket. I hadnt even noticed that until you mentioned it. I checked the gaskets and I have a rubber at the base where it mounts and one where the lens or housing seats in the bucket and then one o-ring where the lock ring tightens up. Am I missing any Rainman? Im not sure what is supposed to be there. Where is it I can order that BD service manual for my 02 Pit anyway? LOL Seriously I need a complete manual, I have the S&S manual for my 107 but that it.

 

[Dray]

Oh one more thing I did find the black wire had melted the socket at the back of the bulb. I cut it off and soldiered a new high temp connector on. I gotta find out whats up with this thing though cause I am blowing bulbs all over, tail light-brake light bulbs, signal indicator bulbs and the speedo backlight bulbs? I have replaced the speedo bulbs but I guess i will have to order the circuit board with the signal indicator and warning bulbs etc.

 

[Little-Boo]

Thanks guys, stlmikie I do have that coil of black wire in the bucket. I hadnt even noticed that until you mentioned it. I checked the gaskets and I have a rubber at the base where it mounts and one where the lens or housing seats in the bucket and then one o-ring where the lock ring tightens up. Am I missing any Rainman? Im not sure what is supposed to be there. Where is it I can order that BD service manual for my 02 Pit anyway? LOL Seriously I need a complete manual, I have the S&S manual for my 107 but that it.

Go to the MAN NELSON via email " sales@wbcycles.com "

by phone " 214-418-3301 "

He can get you a manual and if you want some good lighting

visit Jakes webb site as you mentioned above. You will not be disappointed.

Carlos

 

[Raywood]

I gotta find out whats up with this thing though cause I am blowing bulbs all over, tail light-brake light bulbs, signal indicator bulbs and the speedo backlight bulbs?

You have a "spiking" issue it seems. You need to break out the volt meter and start checking things. I would go over that wiring very carefully again. Something is not right.

Good luck

 

[CCRainman]

Exactly what Ray said. Check you rwiring. The coiled up wire is to prevent surges. If it melted, then you have a problem. While your at it change out the the socket, some of them were bad. It sounds like you have all the gaskets.

 

[ZZ CHOP]

Dray sure sounds like a lot of bulbs blowing. on a 02 does it have LED's or incandescent bulbs? have ya noticed any surging in the lights i think i would check the VR and make sure its not over charging. good luck..Dave.

 

[Guillaume]

Headlight
The headlight assembly is the same as earlier models but the path of electrical current is different
for all 2003 models and the headlight harness also has a change. In 2002 and earlier models the
EHC relay is a starter relay but for 2003 models this relay is the headlight relay (see Figure 19).
The headlight will be on when the ignition switch is in the ON position but will go out when the
starter button is depressed. This is to reduce voltage drop to the starter when activated. As soon
as the starter button is released the relay coil is de-energized and the headlight will come back
on. The headlight relay also controls current to compression releases if they are installed during
starter engagement. If a problem exists with the headlight and all wiring is found to be good then
change the relay in the EHC. Refer to the schematic for relay terminal connections.
The harness that connects the headlamp to the system has a choke (coil) in the ground lead (see
Figure 20). The coil is to help eliminate current spikes in the case of a loose connector that could
blow headlamps. To help eliminate possible headlamp failures, always make sure that the
connector fits tight on the lamp. If the connector becomes loose, heat will be generated at the
loose terminal in the connector and could melt down.

 

[Dray]

Thanks Guillaume, Sounds like some very good information. I will check these things out. I was considering isolating the circuit and installing a weather proof toggle switch under the tank and running the feed directly from the battery with a fused circuit? Just not sure if thats the way to go or not, I think I will save that for a last resort! Did you learn thid from experience or were you able to find the information somewhere. I have got to get a service manual !