Keep blowing out headlights

As I was getting ready to go on a trip I noticed that both beams of my headlight were out on my 77 KZ1000. I replaced it with a GE bulb from Wal-Mart that had identical markings to the one that was in it. I made it less than 100 miles and low beam went out. Made it the rest of the way on high beam. I replaced the headlight with another from Wal-Mart and made it about 200 miles and low beam went out again. I checked voltage at the battery at idle and it was 12.6 and didn't seem to go up much when I brought rpm up to 4k. I unplugged the regulator and plugged it back in and now when I bring rpm up to 4k it slowly starts to come up. It never makes it go 14 volts.

What do think is happening to my headlights? Could my regulator be failing and spiking sometimes?

Any other bulbs affected? instrument,brake and tail light? turn signals? I'd think if one went others would go too.

I'd remove the headlight and look inside the housing for signs orf wires rubbing and shorting. Also check the fuses and fuse clips for corrosion.The glass tubes fuses can fail or become intermittant.

All other lights are working fine. I've only owned the bike for a little over a year, but the fuse box looks to be a replacement and is in great shape. Also, the headlight socket looks to have been replaced and is in good shape. I tested the first two headlights that went out, and they were bad. This has me stumped. Plus, I'm now out $30 for headlights.

For the money I've put out already, I'm really thinking about using one of the conversion kits that uses an H-4 bulb. It's getting old taking everything apart to replace the headlight.

For the most part auto headlight bulbs do not last in a motorcycle. I had the same problem way back in the early 80s on the KZ650 and finally gave up on auto headlights and have had no further problem. I'd assume GE headlights are now made in China and probably real skimpy on ruggedness. If you do in fact have a problem, look for loose connections, bad grounds ect around the headlight wiring. This can definatly cause bulbs to fail.

You probably still have to disassemble for an H4. Mine has the conversion kit on it and I have to pull it all apart each time.

One thing to check, do you have the stock rubber headlight mounts? Its been mentioned before if the headlights don't have some kind of rubber mounts that it's possible to vibrate them until they break. Mine have very small rubber mounts and I can make about 700-800 miles before one will let go again.

Check your Battery water level. Make sure your headlight housing is tight and not moving around and loose....Russ

Russ Jackson wrote:

Check your Battery water level. Make sure your headlight housing is tight and not moving around and loose....Russ

Check your voltage regulator - if you find you are cooking the water out of the battery as Russ suggested you check, that will blow headlights for sure.

KawiConvert wrote:

Its been mentioned before if the headlights don't have some kind of rubber mounts that it's possible to vibrate them until they break. Mine have very small rubber mounts and I can make about 700-800 miles before one will let go again.

700-800 miles between headlights? That would drive me nutz! I haven't replaced a headlight in.....damn I can't remember replacing one! I either got a #1 case of Al Zimer's Syndrome or I got's some sweet lights. You gotta mean 7,000-8,000 miles....right? :huh:

fordtruck wrote:

I checked voltage at the battery at idle and it was 12.6 and didn't seem to go up much when I brought rpm up to 4k. I unplugged the regulator and plugged it back in and now when I bring rpm up to 4k it slowly starts to come up. It never makes it go 14 volts.

That sounds like a bad reg unit, alternator or battery. The batt voltage should rise to about 14V pretty rapidly when the engine is revving above 3k.

I'm putting my money on a vibration issue.
I had the same thing going on with MY 77,ans it WAS the grommets(lack of) at the headlight bucket,where the signals tie in.

I was blowing a headlight every other ride out,and after checking all the electrics,I headed to the headlight bucket and put in extra grommets that I made up...never had a problem since,and it's been 3 or 4 years now.

Thanks guys for all the suggestions, I really appreciate it! It'll be a couple of days before I can look over the bike, but I will check everything that was suggested.

It does have the rubber grommets on the headlight mount. I do remember seeing them

Locozuna wrote:

KawiConvert wrote:

Its been mentioned before if the headlights don't have some kind of rubber mounts that it's possible to vibrate them until they break. Mine have very small rubber mounts and I can make about 700-800 miles before one will let go again.

700-800 miles between headlights? That would drive me nutz! I haven't replaced a headlight in.....damn I can't remember replacing one! I either got a #1 case of Al Zimer's Syndrome or I got's some sweet lights. You gotta mean 7,000-8,000 miles....right? :huh:

Nope, so far about 800 on average if it blew out today. I just need to modify the bottom to use some grommets and it will be fine. Just made the mounts too rigid when I welded it up.