2005 XL Custom headlight dim??

[Camera108]

My wife's 1200 XL Custom has a dim stock headlight. Compared to my 06 Street Glide and 02 Dyna, her light is very dark. Even when I changed to a Silver Star bulb, is is almost invisable during the day. I think I have the light "aimed" right as it hits the garage door the same spot as the other bkes.

Is there something I am missing? I don't know if a connector is not good or bad ground somewhere. I really hate taking it to the dealer and sounding like a putz....."dau.. my headlight don't work right". I tried the HD maintance manuals, no clue,,,that was a $100 + well spent so far. Tried checking the wiring & connectors in the shell and under the tank, but moving the wires did change the output.

I hate trying one of the high output bulbs, and checking out other Sportsters on the road isn't much help as they all seem brighter but I don't know passing them if they have the 05 type light. My 02 and 06 have different lenses, and both are much brighter when coming at you on the road.

Any hints or help would be appreciated. Thanks
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[wharrah]

It sounds like a BAD GROUND connection to me... I can't tell you where to check it, but the description reeks of poor continuity to ground and the headlight is getting partial return thru another light in the circuit...

Good luck

[Camera108]

Thanks, I will start checking this weekend.

Per someone's post here, I cannot say its my wife's bike, but who ever owns it in my house wil be glad to have it fixed, and may continue to let me ride it from time to time. And I will fell safer for both of us. If I get it fixed, I will post the reason so anyone else may benefit.

Thanks again,
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[wehohl]

My wife has same problem with 2006 1200L. The dealer checked it and said it was fine, but when riding in a group, her headlight is not nearly as bright. Have you found a fix for that yet?

[Camera108]

Well, I pulled evey connector I could get to, and connected, reconnected about 3 times, From headlight bulb connected to following the path under the tank. THEN I reaimed the headlight during day until I could see the light brightly when sitting in my Explorer about 25 feet away. Much brighter, enough that at night she gets flashed for bright lights. I may have to lower it agin as it lights the trees and signs but not much of the road on high beam. With the new lens/reflector on the smaller Sportster/Dyna, the back of the reflector needs to be higher aimed to show to the drivers. My 7inch headlight (Street Glide) with the new reflector has more area to show traffic.

I just will play with aim the next couple weeks. If this is still a problem, I will try buying a Softtail light. They are bottom mounts like 1200 Custom, and buy the Softtail dual bulb kit. It only shows Softtail because they didn't put 120 Customs on for some reason. I may try the kit first, then the light bucket if need be. Hope this helps some.
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