Headlight out

[oldcarsarecool]

Ok, I need suggestions. 03 bulldog completely stock. Last couple days I noticed high beam indicator would flicker when I was accelerating. Only when I was moving and it wouldn't be very bright. The headlight would be on low beam. high beam would work when I hit the switch. Today when I was leaving a concert I turned key on and high beam indicator was lit. I thought maybe some kids had hit my headlight switch to high. Wrong, no headlight at all. I switch from low to high and indicator stays on but no headlight. All other lights works, taillights, brake and turn signals. Where do I go from here?

 

[woodbutcher]

first, open up the bucket and check the bulb and then the plug the bulb goes in (sometimes the plastic ones melt). then while you are in there make sure the ground is in good shape. then start tracing the wires back checking for bare wires/ breaks in the wires/corroded connectors. then you start with the switch.

 

[oldcarsarecool]

Ok I'll check it out tomorrow. It's just one bulb with 2 filiments correct? Opening the bucket is straight forward? My service manual is horrible for any kind of details. Thanks, Les

 

[Brew]

You are correct one bulb with 2 filaments, try not to touch the bulb with your bare hands. Wear gloves if possible, your bulb will last longer...:2thumbs:

 

[woodbutcher]

2 set screws on the bottom of the bucket, 1 for trim ring and 1 for inner ring. don't be surprised if the trim ring is a bitch to get out. once you get it out, before you put it back in, you might want to use some anti-seize on the threads.

 

[oldcarsarecool]

Thanks guys I'm going to work on it later today and will post what I find. Does any one know if bulb is interchangable with Harley? I'm hoping all I need is a bulb.

 

[Slick-Dog]

One other thing to check is the ground wires on the frame.... on left side of battery (facing the back) Thats what happen to mine... the headlight & speedo are on the same ground..(3wires total).... Mine did the same thing.... Lets us know!!

 

[oldcarsarecool]

Update. I checked the ground by the battery first. That was good, clean and tight. Next I took the headlight apart. Was not too bad getting the 2 rings to unscrew. Thanks to Woodbutcher I knew about the set screws underneath. I would not have seen them because of my tool bag under the headlight. Anyway, pulled the lens out and disconnected the plug and I could see corrosion on 1 blade of the bulb. Looked closer at the plug and its melted. Tested the plug with my meter and sure enough no power at that connector. I do have power to the other connector. So I guess I'm ordering a new ceramic plug. Maybe I'm reading to much into this but 1 thing puzzles me. I also tested the bulb by leaving it in the lens and connecting alligator clips to the blades. I knew which side was the ground from my meter so i connected that one to the frame. And then taking turns touching the other to the battery. Both high and low came on depending on which connector I was using. My question is why wouldn't the light work in the bucket if I'm getting power to at least 1 connection?

 

[woodbutcher]

because of the corrosion, the EHC may have been reading too much resistance (also, there is a JST connector under the tank for the headlight harness which is the culprit of some BIG trouble. do away with it if you are that deep into it.). make sure you use dielectric grease when putting connections back together and not a bad idea to use shrink wrap, also make sure the pins and sockets in the connectors fit back together properly, they tend to move without being noticed.

 

[oldcarsarecool]

I ordered a plug off ebay. Hopefully I'll get it by the end of the week. What's the reason for the coil in one of the wires. That happens to be the connector that melted.

 

[oldcarsarecool]

Ok, got the new plug and spliced it in. Works good. Little problem keeping lens straight while tightening trim ring. Put 70 miles on bike and no problems so I guess its fixed. Thanks for all the insight everyone.