Headlight bulbs keep burning out

[ChopperJeff]

Ever since I replaced my headlight bucket, I cannot get a bulb to last more than a few days.

First I found the small connctor under the tank wasn't being held together. I fixed that thinking that the loose connector could have been the culprit, but I'm back to square one. Then I found that the plastic piece that goes in front of the bulb kept coming loose. I tightened that up, and the next bulb lasted all of one day.

Yesterday I made sure the thing was wired correctly by comparing it to my Harley's headlight, and all is as it should be.

The headlight bucket I got is the Cobra II, and is the same size as the stock one, so I can't see why it would be an issue. I've order a new headlight wiring harness from Big Dog and will give that a shot.

Can anyone think of a reason for this to be happening?

Sure is frustrating as all hell, especially considering the fact I'm an electronic test engineer/technician by profession, and I can't get a f**king bulb to work right!!! :bang:

 

[npb4me]

Bad voltage regualtor? Maybe it is getting more then 12-14 volts, like a spike, and it is burning up. Also, when you install the new bulb, be sure you never touch the glass. The oil from your fingers can cause a bulb to crack and burn up.

 

[Gas Man]

Yeah, check the voltage at the battery with the bike running.

be carefull when handling the bulbs... your finger oils are hell on the bulbs.

And like Sul said.. check those...

 

[Sparks]

I thought I had an issue with my headlight a few days ago when I fired it up to ride to work. It would come on with the ignition then crap out when the bike started/vibrated. I went back to the source (EHC) sure enough the plug had worked it's self off the clip some how sitting still in the garage while it was snowing out side. I pushed it in untill seated and pushed the clip together/closed to keep it from comming loose again and off I went with a functional head lamp. Damn gremlins never seem to hibernate!

 

[chacha]

Sparks wrote;

I went back to the source (EHC) sure enough the plug had worked it's self off the clip

Got a zip-tie around mine for that exact reason...keeps the plug from vibrating off.

 

[CCRainman]

It could be a vibration issue. I burnt out 3 bulbs before I figured that out. Some aftermarket buckets don't come with the gasket that seals the lamp to the bucket which is right behind the rings. I took the gasket out for a better fit and that solved my problem. When I had the gasket in , it didn't seal the headlight well enough and the vibration caused the light to burn out. Just my 2 cents.