Headlight problem.

[Bperk]

2003 Big Dog Bulldog
I replaced the EHC because of intermittent turn signal issues and now I have a headlight that works fine with key on power but once I fire up the bike the headlight and front turn signals flicker, works fine, shuts off, come back on or won’t come back on. Simply erratic behavior for the headlight and front turns with no rhyme or reason to when or where it’s going to act up but only when the bike is running

 

[Mikeinjersey]

2003 Big Dog Bulldog
I replaced the EHC because of intermittent turn signal issues and now I have a headlight that works fine with key on power but once I fire up the bike the headlight and front turn signals flicker, works fine, shuts off, come back on or won’t come back on. Simply erratic behavior for the headlight and front turns with no rhyme or reason to when or where it’s going to act up but only when the bike is running

Welcome from NJ,
The last thing you did was to replace the EHC. I would go back and double check all the connectors and ensure they are seated firmly and also no backed out wires. Disconnect the battery (-side first then +pos side) before checking the EHC and when you reconnect, clean and tighten the Pos side first and then the Neg. Check battery ground (-) to frame as well.
Consider, you may have replaced the EHC unnecessarily and just changed the symptom. If you think that is a possibility swap your old EHC back in and see what happens. Just a troubleshooting technique if you need it.
Page 8 for grounds check figure 12 & 13

 

[Bperk]

Thank you for your advice. I have checked all connections into the EHC and have not found anything the loose or any wires that have backed out. I haven’t disconnected the battery yet but I will do so. I have checked where the battery grounds to the frame and all looks good there. Stay tuned!

 

[HMAN]

Take a look INSIDE the headlight bucket to make sure the plug hasn't started melting. It happens. Replace with ceramic plug

 

[Mikeinjersey]

These may be helpful.

 

[Bperk]

Thank you for your advice. I have checked all connections into the EHC and have not found anything the loose or any wires that have backed out. I haven’t disconnected the battery yet but I will do so. I have checked where the battery grounds to the frame and all looks good there. Stay tuned!

Welcome from NJ,
The last thing you did was to replace the EHC. I would go back and double check all the connectors and ensure they are seated firmly and also no backed out wires. Disconnect the battery (-side first then +pos side) before checking the EHC and when you reconnect, clean and tighten the Pos side first and then the Neg. Check battery ground (-) to frame as well.
Consider, you may have replaced the EHC unnecessarily and just changed the symptom. If you think that is a possibility swap your old EHC back in and see what happens. Just a troubleshooting technique if you need it.
Page 8 for grounds check figure 12 & 13

Pretty sure I found the culprit. two small black wires and a bigger black wire were broken at this eyelet grounded to the frame.
I assume two smalls are the front turn signal and the bigger is the ground for the headlight. I was so focused on the new EHC I forgot the basics.
thanks for the advice!
the new EHC was replaced for an entirely different reason. For now I think I’m good. Too rainy in NE Ohio tonight for a test ride but if I were a betting man I’d say I’m good!
Thanks to all that replies to my post!!

 

[Mikeinjersey]

Good News !

 

[SCC007]

That'll do it