Headlight Intermittent?

[roedog]

Turned on the key and noticed the blue led light was on, which is for the brights on the headlight. But I did not have the brights turned on and noticed the headlight was not working. So I tapped on the headlight and puff it started working. Then it happened again after I shut off the bike for about an hour or so. Tapped on it again and it started working and worked the rest of the night ok.

Not sure if the headlight connector has bad connection or bulb is going out?
Has anyone experiened this on an 03 Mastiff?

Thanks,
Sean

 

[chacha]

Recommend pulling the lamp assembly and checking the plug. A search of the site will give you several reasons as to what may be going on here....

 

[Loafington]

There was a recall for the plug assy. for the headlight. I am not certain if your bike falls under the recall or not but it is worth looking at. When mine started acting up, I found my headlight wiring inside the headlight bucket was melting and grounding out on the bucket.

 

[bdmridgeback]

More than likely the filament is broken but still touching each other when you tap on it. When it cools off it contracts and doesn't work the next time you turn the bike on. I would say just replacing the bulb will fix your problem. Just inspect the connector while your replacing it. Also, buy a good bulb, not a Autozone or Advance Auto cheapie. Buy a Sylvania if you can.

 

[roedog]

Thanks guys, I'll check it out when I get time.
I bought a PIAA plasma bulb awhile back from Cycle Gear here in AZ.
Hope new bulb fixes it, I was just hoping it was not not the EHC or something wierd going on like that. I hope I can take apart the headlamp assy. without fucking it up, looks like a pain from Gas's how to.

Sean

 

[bdmridgeback]

Easy!!! Those PIAA Bulbs have a lifetime warranty if you didn't know.

 

[roedog]

Ok I took apart headlamp assy, was not that bad, Ha.
I found the headlamp plug melted on just the ground wire connector slot?
How do I find out if there is a recall? Can I just use a standard plug from a bike shop to replace if I go this route? How do I prevent this from happening again? I read somewhere about how it's not grounded properly, should I change the ground location and get rid of all the extra coiled up wire inside the headlight bucket? Sorry so many questions....

Thanks,
Sean

 

[stlmikie]

If im not mistaken the coiled up wire it to help protect from a surge? It too will help with the longevity of the bulb.

 

[Loafington]

The new plug that was installed on mine is a plastic that can withstand the temperature that inside the headlight housing sees. I suggest you contact your Big Dog dealer and ask them to fix yours as they did mine. I would be surprised if they refused seeing how it was a recall item for most.

As far as the extra wiring that is coiled up in there. I was present during my fix and that extra wire made it possible for the service technician to pull the headlight assembly out far enough to work on. You could probably shorten it somewhat but I would leave a little there so you can still work on it.

 

[stlmikie]

Maybe we are talking diferent wires. The one I am talking about is about 10 or 20 feet in length. Rolled tightly around a finger.

 

[chacha]

Roedog;

Have them pull Service Bulletin 1077. The replacement plug is in kit number 173-000012-00.

On the coiled wire bit - this was an attempt to field repair early version EHC ground issue to the headlight bucket. I chaffed it and ran the ground to the bucket itself a long time back. Yet another reason the EHC and harness are coming out this winter....

 

[roedog]

Roedog;

Have them pull Service Bulletin 1077. The replacement plug is in kit number 173-000012-00.

On the coiled wire bit - this was an attempt to field repair early version EHC ground issue to the headlight bucket. I chaffed it and ran the ground to the bucket itself a long time back. Yet another reason the EHC and harness are coming out this winter....

Chacha,

Thanks for the info, I called the BD dealer here in AZ and they told me that there are no recalls on this model for this plug? So I'm just gonna replace it with a standard one I got from an HD dealer. I'll just leave the coiled ground wire as is.

Thanks to everyone,
Roedog

 

[chacha]

Well - I suppose he can claim that since the SB only calls out 2004 and up models. The HD plug should be more than fine....

 

[CCRainman]

Roedog, change out the socket with an HD one or go to the auto parts store and get one. Do not remove that coiled up wire whatever you do. It serves a purpose but I forgot what exactly. I need to refer to the manual for that. You shouldn't have any problems with your EHC since it's an 03. It's alll the newer bikes that have that problem.

 

[bdmridgeback]

After I removed my EHC and installed the Wire-Plus module, I eliminated that 5 feet of coiled wire and grounded the plug in the socket along with the factory ground at the battery.