mleach72
Well-Known Member
As some of you know, my buddy Tommy bought Paul's bagger a few months ago. The bike ran great 99% of the time, but it had an occasional stumbling issue. Sometimes it would shut off completely. It kept throwing high voltage codes for the battery and some of the sensors. We checked all of the connections. Checked the headlight plug. It wasn't melted and looked to be in good shape. We replaced the voltage regulator, ignition switch, and plug wires. We couldn't get rid of the stumbling issue. It was really frustrating! I could tell it was really starting to wear on Tommy as well. I was starting to run out of ideas. I started to wonder if there was an internal problem with the daymaker headlight. I figured I'll swap in the one from my bike and see if that makes a difference. To my surprise, when I went to unplug the light, one of the contacts slipped out of the female plug. The other two were very loose too. I could pull them right out without putting a screwdriver in the plug to bend the tabs down. I bent the tab up on all of the contacts and put them back back in. When I plugged the light back in, it was much tighter. It's been 3 days now. I've ridden it quite a bit with no problems. I think I finally got it! I wish I had done a more thorough inspection of the headlight plug to begin with.
