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Discussion Starter #1
I upgraded my head light to a much brighter bulb. During my first ride with it it quit working. I'll check connections, my question is with mounting that box that everything runs through. I watched the video and he says to zip tie it yo crossmember. I did but I noticed that it's moving around. Any other ideas?

Thanks
Bryan
 

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Check ground wire
 

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I know what you mean about the ballast being hard to mount securely. I zipped tied the heck out of mine and I am fairly confident that it is good but I do need to inspect it again and make sure.

I suspect a ground wire as well. I pulled mine off when installing the new LED bulb set up and it is a real bugger to get back on without taking apart the fairing.
 

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Check ground wire
+1 The ground connection in the headlight is notorious for coming loose.

On the mounting I have gone to using industrial Velcro and have the ballasts mounted to the nose cone on either side of the headlight. I used a home use Velcro the first time and it didn't like the heat from the sun on the plastic. So far the industrial is doing fine.
 

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Miles of Smiles
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∧ +1 on Industrial Velcro. Called Dual-Lock here.
The top of the headlight shell fits the plate I made really well.
A tip from this site on these ballasts, ( not sure about others ) was
to reverse one cover to allow both power leads to exit from the case
at the back. Positioning helps with cable run and easy to do.
Not keen on temporary zip ties myself, but this farkle has stood up to
the test of time. The ballasts on the aluminium plate have never moved.

Cheers
 

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Discussion Starter #6
Yup the brown wire came loose. Thinking about getting rid of that plug and wiring different connectors. I really like the Velcro idea as even with 3 zip ties I know it will be in the back of my mind, is it coming loose again. I'm going to make a plate for it to Velcro to. I live in AZ so heat is definitely an issue.
 
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