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1993 FLHS headlamp trouble

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Old Sep 1, 2011 | 10:36 PM
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Default 1993 FLHS headlamp trouble

Help!!! Intermittently, when starting my 1993 FLHS Electra Glide Sport, I turn the ignition switch to the "on" or "start" position and the headlamp will NOT illuminate. All other lights will come on and bike will start and run normal. When this happens, the high beam bulb indicator will illuminate in the dash, even though high / low beam switch is in low beam position. The last time this happened, I took the seat off, wiggled the battery connections (which are tight) and turned handle bars back and forth, then turned ignition switch on and headlamp was working normal.
I have recently replaced the battery because old battery had died and leaked acid all over the place. I have cleaned spill with baking soda and water solution. I also had to replace the starter relay, as acid had made its way inside the relay, causing it not to work.

Bike is completely stock
Any input would be greatly appreciated.
 
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Old Sep 1, 2011 | 10:44 PM
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My Ultra had just started doing this a couple weeks ago, mine turned out to be a loose pin in the headlight connector. Couple minutes with a screw driver and a soldering iron and she works like new.
 
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Old Sep 3, 2011 | 09:26 AM
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Thanks Nick, I removed the headlamp to inspect the headlamp bulb connector. found one of the terminals had overheated and partially melted the plastic connector. First order of business will be to replace headlamp bulb connector. Second order of business will be to find and clean the ground. Sounds like this should take care of my issue.
 
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