Headlight is a no-go

Energy One
W

wes_b34

New Member
I just recently purchased an 04 chopper and after 2 weeks of riding the i lost the dim, then a few days later lost high beam. I removed the light and retaining rings, and found the ground is melted on the plug. I then found a ground to frame wire behind the battery is not connected to anything. Please give advice!!:confused:
 
1BADK9

1BADK9

Limited Edition Member
Welcome to the site Wes, there has been many melt downs of the plastic head light bulb holder part. They made a ceramic replacement. Sounds like the short caused that ground wire to burn also. A new ceramic bulb holder and repair or replace that wire and you should be back in business. Use the search feature and you can find many similar experiences and the repairs they did. Again welcome to the forum.
 
W

wes_b34

New Member
I have looked at many wiring diagrams, but I cant figure out where the ground wire came from, also where do you get a ceramic plug?
 
Brew

Brew

Troop Supporter
Plenty of ceramic plugs for sale on Ebay, just have to look for them...:2thumbs:
 
W

wes_b34

New Member
found plug thanks guys, still not sure about this braided ground. Cant really locate it on the diagrams. Does it go to a harness somewhere?
 
BigDogBro1

BigDogBro1

Made in the USA
Follow it and see where it leads you....

It could have been an owner add-on or a modification. These bikes run all separate grounds for everything. That way they made sure there was a good ground for the electronics and didn't rely on frame ground connections.
 
echoniner111

echoniner111

Active Member
No prblems with my headlight as far as wiring.

Mines just not bright enough, I've replaced the bulb, still didn't help. I ride around at night with high beam and still not safely bright enough.

????
 
erldawg

erldawg

Guru
echoniner111 said:
No prblems with my headlight as far as wiring.

Mines just not bright enough, I've replaced the bulb, still didn't help. I ride around at night with high beam and still not safely bright enough.

????
Click to expand...
Get out the wiring diagram and check ground wires and or follow them. Sounds to me like a poor ground.

Wires come from headlight into plug under gas tank then to EHC......Dielectric the connections...

http://www.bigdogbiker.com/forums/attachments/technical/457d1202952106-2006-2007-wiring-schematic-diagram-wire_diagram_-.pdf
 
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BigDogBro1

BigDogBro1

Made in the USA
Pull off the seat and RH side cover and FOLLOW THE BRAIDED GROUND WIRES. My 07 Bulldog has those as well but I've never bothered to trace them back.

If your side covers attach with screws....there is a cover attach UPGRADE kit that uses new grommets and aluminum push pins. The earlier cover attachment used captivated nuts in a rubber expansion bushing and a screw. Overtightening the screws caused the cover mounting ears to crack and undertightening them let the covers fall off! Before I got the upgrade I safety wired the cover screws. Yes, you need to drill holes through the heads of new stainless socket head cap screws.
 
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W

wes_b34

New Member
Ok, replaced old plug with ceramic, and replaced headlight.... Still nothing.:confused: Also the braided ground is only about 2in long right beside the neg bat cable. And I noticed when I tried turning brights on a red light come on the "ehc" under the seat.
 
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BigDogBro1

BigDogBro1

Made in the USA
wes_b34 said:
Ok, replaced old plug with ceramic, and replaced headlight.... Still nothing.:confused: Also the braided ground is only about 2in long right beside the neg bat cable. And I noticed when I tried turning brights on a red light come on the "ehc" under the seat.
Click to expand...
That sucks!...Ya think it might be a Bad bulb?

I would reconnect the grounds. There is a small bolt near there where mine secures to.

Are you sure you connected the new headlight bulb ceramic connector up good and correctly?

Not sure which EHC RED LED you are talking about. It's a fault condition LED. Use this link below for 2004 and tell us which LED it is.
If the EHC senses over or under current draw in the circuit it will shut it down and cause a fault LED.
http://www.bigdogbiker.com/forums/how/3717-read-your-ehc-fault-lights.html
 
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W

wes_b34

New Member
Also when I turn brights on I can see a faint bright symbol on speedo. Its the high/low led
 
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Brew

Brew

Troop Supporter
Are you doing this when the scoot is running? I would put a meter on your battery posts with the scoot running and make sure your charging system is putting out the correct current as a quick check. At least you can eliminate that aspect of the issue...
 
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