Headlight went out- please help

[bigchazz]

Riding with no issues, just as I got home, in the driveway, the headlight went out, will not come back on, all other lights work fine. A little background. My ignition has three positions, off, on, and on with lights. I assume its not the stock ignition because the key has a Harley symbol on it, so I assume it has been changed. The light control only has one position, no dim or bright position, lights are only dim, has always been that way and really doesnt bother me that I dont have brights. Any help with where to start looking, how to check the light, is there a fuse, any place to check wiring, should I replace the ignition, .......thanks for any help.

 

[stryfox]

First step would be to disassemble the head lamp bucket and check the bulb. Then check the wiring for power and ground.

 

[Little-Boo]

Sounds like your high beam went out and now the low beam which tells me you should replace the bulb. The bulb is a 55/60 W H-4. You can find them at walmart.

 

[liferider]

try to find this. They are hitting the market this month. Lifetime warranty. I was on the trial team along with 99 other people. I have 2 one in my bike and 1 in my T-bag with my tools to replace it with.

 

[bigchazz]

Thanks Little boo, I will start there

 

[Jersey James]

try to find this. They are hitting the market this month. Lifetime warranty. I was on the trial team along with 99 other people. I have 2 one in my bike and 1 in my T-bag with my tools to replace it with.

How do you like the light it throws? "Hitting the market", where??? Thanks

 

[Jersey James]

bigchazz: When you have your headlight apart, I would also check the three prong plug, they have been know to go bad.

 

[KaptinAmerika]

Beyond liferider's suggestion, I have no experience with that product but they are a bit more expensive, the only bulb I have found that lasts is the Sylvania "Silverlight" or "Silverstar" ultra HB2. Available at just about any auto parts store.

 

[Cavazos]

bigchazz: When you have your headlight apart, I would also check the three prong plug, they have been know to go bad.

my plug was fried when i opened up my headlamp. let me know if yours is, i have an extra plug at home, i'll take it on wednesday.

 

[Fat_Bastard]

Hi,
Headlight problem...

I hope it is not like mine. I have a 2004 Big Dog Chopper and the headlight problem started out just like yours, months ago. Did all that stuff: replaced bulb, battery, checked grounds, switches; then voltages at headlight connector BAD--traced it back to EHC, no 12 volts from EHC (10.5 volts DC don't light it up see below).

My "EHC" symptoms are:
a) months ago Low-Beam started to intermittantly go out; had to use Hi-Beam only; All else was OK.

b) got New Battery and trickle charged every night. Problem went away two months ago.

c) one month ago Low-Beam out again, Hi-Beam only; bike randomly just lost all power to spark plugs while riding; continued to quit electricaly (no spark, but other lights, horn, turn signals OK, but no Hi-or-Lo beams) Let it sit by side of road for ten minutes then could start and ride it home. (I knew no spark by carrying spare spark plug I connected and held to side of cylinder while cranking.) no signs of weak new battery. All else was OK.

d) rode home, checked voltages:
on same New Battery: 13.5 while on charger, 13.1 off charger; 12.5 dip at startup cranking; started engine --running it charges immediately to 14.2 volts, seems OK. But no Headlight at all.

e) Checked Headlight voltages at bulb connecter:
Yellow wire 10.5, White 7.5; with key ON or engine running. (of course checked/swapped bulbs and jumper wired temporarily off battery to be sure all were working ok).

f) Pulled Connecter to Headlight under gas tank and measured same exact voltages as at Headlight connector; Yellow wire 10.5, White 7.5; Checked ignition wire 12.1 volts.

g) Checked voltages at EHC 50 pin connector while connected and ignition key ON: pins 16 & 17 same yellow and white wires to headlight, same voltages 10.5 and 7.5

I think this means my EHC is bad --cannot get 12 volts out of the EHC to headlight...

I can only ride with no headlights for 9 miles or fifteen minutes and bike quits per item c) above. Systems charges because engine cranks fine and all other lights OK all the time.

Just my thoughts... OK back to my Big Mac and Supersize Meal.


UPDATE 7-5-2012
****EHC was in fact Bad****
Just got my Wire Plus Kit and Ignition Key Switch (after a Loooooooong Wait, 3 months!)

It has fixed all my problems per above, bike runs great now even seems slightly stronger at low rpm and idle --perhaps the failing EHC was not allowing strong voltages and current to other areas...

All in all I feel a strong Nuetral to the whole Wire Plus Solution. My 2004 Chopper had no PDM alternative product offering. Third choice was to rewire Harley style -- out of the question for me, too much money. Had no other reasonable choice; So for $500 and change I expected more from Wire Plus -- a "plug and go" solution.

Pro and Con:
Con:
Installation instructions are very poorly written and lack enough proper helpful photos.
(youtube video helped, showed me the wrong way to mount the modules backwards blocking view of LED's; and they probably thought they were showing you the right way, LOL) Many things omitted... -- and all wires and connectors should have come as more of a "plug and go" set up for the $500 plus... I felt they just built two modules and let you build the rest supplying a few pieces of wire and bunch of connectors. Very expensive and they took my money upfront, pretty much ignored my requests for updates and status and a 3 month wait for fabrication WTF!!!

Pro:
It worked.

Nuff said.

UPDATE 9-27-2020
**** Wire Plus still working GREAT!***
...not sure what to do if it ever goes bad... (as far as replacement alternative)

 

[bigchazz]

Pulled the headlight off, buld was fryed, wiring was also a little frayed, also chrome was starting to peel.....sooooo, I ordered a new light thinking to kill multiple problems with one fix.......I havent checked voltages yet, but I will before I install new light. THANKS for the replys, this forum is a big help.

 

[japelfrey]

Hi,
Headlight problem...

I hope it is not like mine. I have a 2004 Big Dog Chopper and the headlight problem started out just like yours, months ago. Did all that stuff: replaced bulb, battery, checked grounds, switches; then voltages at headlight connector BAD--traced it back to EHC, no 12 volts from EHC (10.5 volts DC don't light it up see below).

My "EHC" symptoms are:
a) months ago Low-Beam started to intermittantly go out; had to use Hi-Beam only; All else was OK.

b) got New Battery and trickle charged every night. Problem went away two months ago.

c) one month ago Low-Beam out again, Hi-Beam only; bike randomly just lost all power to spark plugs while riding; continued to quit electricaly (no spark, but other lights, horn, turn signals OK, but no Hi-or-Lo beams) Let it sit by side of road for ten minutes then could start and ride it home. (I knew no spark by carrying spare spark plug I connected and held to side of cylinder while cranking.) no signs of weak new battery. All else was OK.

d) rode home, checked voltages:
on same New Battery: 13.5 while on charger, 13.1 off charger; 12.5 dip at startup cranking; started engine --running it charges immediately to 14.2 volts, seems OK. But no Headlight at all.

e) Checked Headlight voltages at bulb connecter:
Yellow wire 10.5, White 7.5; with key ON or engine running. (of course checked/swapped bulbs and jumper wired temporarily off battery to be sure all were working ok).

f) Pulled Connecter to Headlight under gas tank and measured same exact voltages as at Headlight connector; Yellow wire 10.5, White 7.5; Checked ignition wire 12.1 volts.

g) Checked voltages at EHC 50 pin connector while connected and ignition key ON: pins 16 & 17 same yellow and white wires to headlight, same voltages 10.5 and 7.5

I think this means my EHC is bad --cannot get 12 volts out of the EHC to headlight...

I can only ride with no headlights for 9 miles or fifteen minutes and bike quits per item c) above. Systems charges because engine cranks fine and all other lights OK all the time.

Just my thoughts... OK back to my Big Mac and Supersize Meal.


UPDATE 7-5-2012
****EHC was in fact Bad****
Just got my Wire Plus Kit and Ignition Key Switch (after a Loooooooong Wait, 3 months!)

It has fixed all my problems per above, bike runs great now even seems slightly stronger at low rpm and idle --perhaps the failing EHC was not allowing strong voltages and current to other areas...

All in all I feel a strong Nuetral to the whole Wire Plus Solution. My 2004 Chopper had no PDM alternative product offering. Third choice was to rewire Harley style -- out of the question for me, too much money. Had no other reasonable choice; So for $500 and change I expected more from Wire Plus -- a "plug and go" solution.

Pro and Con:
Con:
Installation instructions are very poorly written and lack enough proper helpful photos.
(youtube video helped, showed me the wrong way to mount the modules backwards blocking view of LED's; and they probably thought they were showing you the right way, LOL) Many things omitted... -- and all wires and connectors should have come as more of a "plug and go" set up for the $500 plus... I felt they just built two modules and let you build the rest supplying a few pieces of wire and bunch of connectors. Very expensive and they took my money upfront, pretty much ignored my requests for updates and status and a 3 month wait for fabrication WTF!!!

Pro:
It worked.

Nuff said.

I know this is an old post so I'm trying to understand the difference on my 05 and your 04. The voltages you are checking. In my manual it says that with the exception of 2 or 3 signals everything else is at a reference of 5v until the thunder heart sees a request (ground) then sends the output voltage?

Just trying to confirm then different methods for troubleshooting. I'm going with ohm in off for continuity and the reference voltage should be everywhere until it is requested and then output is given a voltage (12V)? Is my assumption correct?

 

[1 B.M.F.]

Call Curtis at wildsteedworx.com, he is very busy all the time he will call you back. He can answer all your questions. If you haven’t changed your voltage regulator to a new one, You might do that. It will save your EHC if it’s not to late. I have an 04 and 05. My voltage is the same. Everything is low voltage except the starter. Make sure you have a good circuit breaker for you VR to your EHC and battery

 

[Fat_Bastard]

I know this is an old post so I'm trying to understand the difference on my 05 and your 04. The voltages you are checking. In my manual it says that with the exception of 2 or 3 signals everything else is at a reference of 5v until the thunder heart sees a request (ground) then sends the output voltage?

Just trying to confirm then different methods for troubleshooting. I'm going with ohm in off for continuity and the reference voltage should be everywhere until it is requested and then output is given a voltage (12V)? Is my assumption correct?

Hi japelfrey,
I even direct wired the headlight off the battery just to see the headlight work and to ride around. But I soon realized this is how the EHC dies a slow death, many other things were going wrong prior to this... and after... Not worth keeping a known questionable critical component around (EHC). No fun when you break in the middle of now where -- or worse yet a bad neighborhood.

 

[WU5C]

In respect to the old thread, I too had issues with the lights. So I replaced my EHC with the one from Dead One Customs. No issue whatsoever. I now run LED headlight and couldn't be happier with the light that it casts down the road. I no longer feel blind at night by lack of headlight. This is the Headlight from Amazon and very pleased with the amount of light that it produces. And it is not going to break the bank.

Wisamic 5-3/4 5.75 inch LED Headlight - Compatible with Harley Davidson Dyna Street Bob Super Wide Glide Low Rider Night Rod Train Softail Deuce Custo