Headlights Blowing Constantly...

So here's the problem I am having:

My headlights constantly blow out. They last approx 100 miles per beam (ride 100 miles, low beam blows, switch to high, blows in 100 miles).

I am thinking it's a vibration problem, although the bike does not really vibrate bad at all unless above 6500 rpm. Most of the time is spent cruising on the highway, 60-80 mph which is about 4000-5000 RPM.

At first I thought it was a regulator/rectifier problem, but I have a Rick's Motorsport Reg/Rec fitted and voltage measures 12.8 key off, 12.5 key on idling, and 13.0-13.8 revving. All good, I assume.

Any ideas?

-Dave

@ Idle with low beams on, what's your voltage drop on the battery terminals?

Then at high beams?

Ya got to have some kind of rubber dampener on the mount. Is it hard mounted?

Yup,sounds like a vibration issue to me as well.Been there,done that.
I was having the same problem,and then I made some more rubber dampeners for the headlight bucket,and all was/is good.

And I too,was going through one,less than every 100 miles.

It's usually one of two things causing headlight failure;
Vibration or voltage surges. If no other bulbs are being blown(instrument,turn signals,or brake light/tail light(s)),then I'd look at the rubber headlight dampners drying out and hardening.

The small instrument bulbs almost always blow first from voltage surges.... guess how I learned that.

I'll bet your light dies from vibration.

I just went through this on my 77 KZ1000. I'd had it for over a year with no trouble, then all of a sudden I couldn't keep a headlight working. With advice from this site I started looking for bare wires in the headlight bucket. I found two brown wires, that were not hooked to anything, that looked like they had been pinched by the headlight. Both of them had the insulation torn off. These two wires are hot when the ignition switch is on. I repaired them and have had no trouble since.

What kind of headlights are you using? If the answer is automotive bulbs, that's the problem. Any bulb bought at the Chinese auto supply places like Wal Mart, Checkers, Auto Zone and the like will not last more than a few days.

RonKZ650 wrote:

What kind of headlights are you using? If the answer is automotive bulbs, that's the problem. Any bulb bought at the Chinese auto supply places like Wal Mart, Checkers, Auto Zone and the like will not last more than a few days.

Ron,I'm using an "Automotive bulb",and it's been in the headlight for a couple years now,working fine.

When I was having problems with bulbs blowing constantly,I tried a "Motorcycle-Bulb",and it blew too.Said it would hold up to motorcycle vibration.

If that headlight bucket doesn't have proper grommets,nothing will work.

I guess maybe it's the luck of the draw on headlight bulbs. I can't remember the specifics, but it was somewhere around 60,000 miles I think the headlight burned out on my KZ650. I went to a Chinese auto parts place and got one, got another, then another, switched brands ect. None lasted more than a few days. I knew it was the bulbs were crap so finally went the motorcycle halogen routt and have not had a problem since. I'd still bet on crap bulbs here. If the regulator is not working and volts are soaring, yes the headlight will burn out, but also the rest of the lights as they would have the same voltage on them. Bad grounds and/or power connections to the bulbs can cause failure too, so look at the wiring, if OK, bad bulbs.

I've got the halogen kit in mine. I've blown 2 so far, but it is from vibration on the road, not the bike. Some of the roads are a little rough and I found those were the ones doing it. Check your headlight bucket mounts to make sure the shock isolators (rubber grommets) are in place and good.

The halogen kit isn't too bad in price, though you can pick up a full glass and halogen replacement bulb unit for a little more than the cost of just the halogen bulbs.

"Chinese auto supply places like Wal Mart, Checkers, Auto Zone and the like will not last more than a few days"...

You can't possibly be serious in this.... :blink: