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Discussion Starter #1
My buddy noticed today that my headlight was not on right before we were pulling out of his driveway. So we took the bulb out and went and bought a replacement(From walmart. Only store open at the time) It was a GE 9003 halogen bulb that matched up to the existing bulb that was in the head lamp. The bulb that was pulled from the bike however was a Japanese bulb with the number 3401 on the bottom of it. The original bulb(3401) is bad as one of the tiny springs broke off and is moving around in the glass. When we put the new one in though the bulb did not turn on. We checked the fuses and everything was good. Is this the wrong bulb? If so will i be able to buy the bulb I need at a local auto shop or what? Thanks in advance Ian.
 

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Premium Member
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I got mine at a local auto parts store. Have done it twice, at different stores. It's a standard bulb. But I use halogen bulbs too. All auto stores carry them.
Not sure about the number on the one you bought.
Could be a bad bulb from the start.
Did you pull it out and re-plug it back in again?
And check your dimmer switch to see that it's in the right position.
Also, start the bike. The light should burn without it started, but when in doubt, check everything.
Might also check the connectors on the wiring--if you pulled something loose when you opened the light bucket up the first time.
 

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Discussion Starter #3
Yes we plug it in and out several times and even had another buddy come over and look at it. Never worked and couldn't figure it out. By dimmer switch do you mean high/low beam if so yes switched back and forth every time we re plugged and nothing. Also we did start it nothing. Check everything we could see for good connections but just to make sure it was connected we did not check voltage.
 

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Before you spend for a new light bulb, you might try putting the old one back in and see if high beam works. If it's not burned out (2nd broken spring inside), you should see it light up. If it does, then go get another bulb that matches the original.
Just a quick and simple test before you buy another bulb....
 

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Nothing else to offer at the moment.
Maybe somebody else will offer something.
If I think of anything--other than go ahead and buy a good replacement lamp and try it...
 

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The Professor
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Your HL relay probably took a crap, it happens alot. At the Junction/fuse box locate the blue wire in the TOP connector and move it to the open slot beside it in the connector. Your HL should now come on when you turn on the key. If it does you can replace the JB or leave as is. :smiley_th
 

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Your HL relay probably took a crap, it happens alot. At the Junction/fuse box locate the blue wire in the TOP connector and move it to the open slot beside it in the connector. Your HL should now come on when you turn on the key. If it does you can replace the JB or leave as is. :smiley_th
Now this makes good sense. Forgot about the relay.
I put a new relay in mine when I wired my ignition switch. Bypassed the junction box altogether--which defeats the safe-on high beam system. But I can live with that. My volt meter wires into my headlight circuit so I can see when my headlight drops out of the system.
 

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The Professor
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Check the voltages from the stator. One of the legs goes to the HL relay, and that is how I found out my stator crapped out. Just a suggestion
 

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The Professor
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All three legs of the stator go to the R/R, none of them go to the HL relay.
 

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The Professor
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My buddy noticed today that my headlight was not on right before we were pulling out of his driveway. So we took the bulb out and went and bought a replacement(From walmart. Only store open at the time) It was a GE 9003 halogen bulb that matched up to the existing bulb that was in the head lamp. The bulb that was pulled from the bike however was a Japanese bulb with the number 3401 on the bottom of it. The original bulb(3401) is bad as one of the tiny springs broke off and is moving around in the glass. When we put the new one in though the bulb did not turn on. We checked the fuses and everything was good. Is this the wrong bulb? If so will i be able to buy the bulb I need at a local auto shop or what? Thanks in advance Ian.
Did you start the bike or just turn the key on?
 

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Discussion Starter #16
alright update bought a new bulb. Still no luck till about 10 mins into ride the light comes on.(it was the middle of the afternoon plenty of sunshine) Then i ride all day and when ever i turn the bike off and then turn back on it comes back on. I park my bike go home for some dinner and when i go back to start it back up the light comes on and then after a little ride it turns off. I finish my short trip to where i was going b/c my buddy was next to me and i could see fine because of his lights. I turn it off and on it goods it turns on so i was like alright ill be fine for when i go home. Well the light doesn't come on when i am ready to leave. Luckily my other buddy had his truck and he drove in front of me kind of like an escort to get me where i"m going. The light turns on after i hit about 45mph so take a lap back to where i was coming from to make sure it is all good. Its fine and I take the bike back to where i store it. Now tomorrow when i check it i have a feeling it is not going to start but then somewhere after about ten minutes it will. Any input will be great thanks.
 

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Old Truck Junkie
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Some times wires will look good. Especially close to the metal connector, but the wire inside the rubber insulation is really broke in two. It is hard to tell when the wire is broken. Wiggling the wires is the best way to find this kind of a break. Hope this helps you.
 
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