I have a 2011 Road King Classic. Recently I began to notice at night a Harley-Davidson headlight problem and passing lamps would blink off and back on occasionally. The Harley Davidson headlight problems worsened and looking at the service manual, I decided the headlight relay must be bad. When I pulled the headlight relay, I noticed some corrosion on the connectors on the relay itself. I ordered a new relay, cleaned the connectors in the fuse box and installed the new relay. That didn’t fix the problem. Now, the headlight does not always come on when I turn the ignition switch on. If I turn the handle bars side to side, the headlight and passing lamps will come on. I took the cover off the fuse box and put my finger on the headlight relay, when I turn the ignition switch on, I can feel the relay click. I’m now thinking that there must be a loose connector or ground wire inside the headlight nacelle, any guidance would be appreciated.
Joe, throw a towel over your front fender and remove your head light bucket. Inspect your head light, head light plug, and harness. Make sure your connections can be secure and are without corrosion. While your nacelle is open, try to get a look at your passing lamp switch and it’s harness. If you do not see anything obvious, plug your headlight in while it hangs loose. Turn on your ignition switch and tug on the related wiring harness. If you can not get the light to go out, move up to your left side switch housing. Tug and poke around that harness while you trace it down into the nacelle. Play with your hi/low switch and your passing lamp switch. If you had a dead short you would be blowing a fuse. This sounds more like a bad connection or a bad switch. Thanks for the question. Let us know how you make out.
I did as you suggested and found a pin/socket combination that had overheated. I also found a non-factory wire in the nacelle that was apparently connected to the back of the headlight plug at one time. There is a shiny spot on the handlebars that indicates a clamp for an accessory mount, maybe a GPS, so I’m guessing someone powered the accessory off the headlight plug. The pin/socket that was damaged was for a yellow wire, same as the wire on the headlight plug. I bought this bike from the local Harley dealer, it was from the “executive fleet”. The oil in the trans and crankcase was clean, the primary was nasty. You’d think those guys would take better care of their bikes! Anyway, I’ve replaced tires and battery and now $34 for a connector, I bought the bike for $4500 less than a new one, so I’m still way ahead.
Thanks for your reply!