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Nigel Hulse Posted on Jul 02, 2016
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Can the use of a higher wattage headlamp bulb damage the regulator?

1 Answer

Bill Boyd

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  • Motorcycles Master 53,816 Answers
  • Posted on Jul 02, 2016
Bill Boyd
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Joined: Jan 04, 2013
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NO
bulbs have nothing to do with regulators
regulators control the voltage of the alternator and therefore the amperage output of the alternator
what higher wattage bulbs will do
if you have plastic reflectors , they will melt the reflectors
if you run too high a wattage bulbs , you will burn the wiring harness to the lights as the current draw will exceed the wire capacity to handle the amps
if you have current 55/65 head light h4 bulbs then going up to 55/85 will be about as high a wattage you can go before you have to consider relays for each bulb and the reflector quality

  • 2 more comments 
  • Nigel Hulse
    Nigel Hulse Jul 02, 2016

    Surely demanding a higher current from the alternator, for higher wattage bulbs, requires a higher voltage from the regulator?

  • Bill Boyd Jul 02, 2016

    NO--- the voltage regulator is set at 14.5to 14.8 volts or else the battery boils
    the voltage controls the current ( amps produced)
    using bigger wattage bulbs only uses extra amps which the regulator adjusts to up to the maximum amperage that the alternator can produce
    So if you have--for discussion-- a 100 amp alternator fitted, the the voltage is set at 14.5 volts and the amps produced will depend on the amps required
    so on starting, the starter draws 500 amps which comes from the battery
    the voltage regulator sets at 14.5 volts to overcome the 13.5 volts of the battery and that pushes amps into the battery until the cells will not accept any more current and so the amps drop of to what is required to run the electronics
    now when you turn on the lights, the requirement is for more amps so the regulator now lets more amps from the alternator to compensate for what is being used from the battery
    for discussion --your lights draw 10 amps and the electronics draw 10 amps you have a need of 20 amps which the alternator now provides through the regulator amps setting and not from the battery
    now we go to extreme and put very large driving lights (200 watts per light) and there are 4 lights
    the amps are now exceeding the 100 amp capacity of the alternator ( still at 14.5 volts) and so after a period of driving the engine starts to falter and stops, because the battery is supplying the extra amps and goes flat.
    it amounts to this- for your line of thinking, the bulbs are 12 volts regardless of the wattage and if you increased the voltage because of the extra wattage then the 12 volt bulb would blow out as they will only handle the 12 volts or 13.5 max from the battery so a 200 watt bulb is still only 12 volts the same voltage as a 5 watt bulb--12 volts

  • Nigel Hulse
    Nigel Hulse Jul 03, 2016

    Thanks for the assistance, Bill. Why I asked this was because the regulator on this bike had blown and I found that the Bulb being used was a 60/55W instead of the recommended 35/35.
    Thanks again.

  • Bill Boyd Jul 03, 2016

    My mistake , I took it that it was a car not a motor bike. however the principle is the same regardless but the reason for the regulator failure may be different
    positioning of the regulator may place it in a hot environment and if fully electronic , that would cause the components to over heat and fail
    for example in a car if the regulator is external to the alternator it is placed on the fire wall or inner guard well away from the engine heat source
    if it is internal in the alternator it is cooled by the fan attached to the back if the pulley
    another point is all regulators are not equal as some manufacturers use components that are working at the limits while others give their components a safety margin to allow for power surges, heat, constant current etc so on replacing a regulator , first determine if there is a circuit problem--- wire damage , dead short etc ( bike auto electrician will have the knowledge) and then invest in a quality regulator not necessarily the OEM brand

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Remove head lamp door on 2003 FLHRCI

HEADLAMP (FLHR/C, FLHT/C/U) HEADLAMP ASSEMBLY

To REMOVE:
First remove the Phillips screw at the bottom of the headlamp door chrome ring and remove the headlamp door. On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing. On FLHR/C remove the eight Phillips screws to free the headlamp housing from the headlamp nacelle. Then if installed squeeze the two external tabs to remove the wire connector at the back of the headlamp bulb. Next remove the headlamp housing assembly from the vehicle.

To RE-INSTALL:
First connect the wire connector at the backside of the headlamp bulb.On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottom of the headlamp door bracket and install the four TORX screws. On FLHR/C align the holes in the headlamp housing with those in the headlamp nacelle at the bottom of the headlamp door bracket and install the eight Phillips screws.
Next fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and then snap the headlamp door chrome ring into place and install the Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is(1.0-2.0 Nm).

To Replace the Headlight bulb:

The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.

First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.

HEADLAMP (FLHR/C, FLHT/C/U)
HEADLAMP ASSEMBLY

To Remove:
First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. On FLHT/C/U remove the four TORX screws to free the headlamp housing from the fairing. On FLHR/C remove the eight Phillips head screws to free the headlamp housing from the headlamp nacelle. THEN, if installed, squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb and remove the headlamp housing assembly from the vehicle.

To Re-Install:

First install the wire connector at the back of headlamp bulb.
On FLHT/C/U align the holes in the headlamp housing with those in the fairing at the bottom of the headlamp door bracket and install the four TORX screws.
On FLHR/C align the holes in the headlamp housing with the holes in the bottom of the headlamp nacelle headlamp door bracket and install the eight Phillips head screws. THEN fit the square-shaped portion of the headlamp door spring into the slot at the top of the headlamp housing and snap the headlamp door chrome ring into place and install Phillips head screw at the bottom of the headlamp door and tighten it to 9-18 in-lbs which is (1.0-2.0 Nm).

To replace the headlamp bulb:

The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.
First remove the Phillips head screw at the bottom of the headlamp door chrome ring and remove the headlamp door. THEN remove the three Phillips head screws to free the retaining ring from the headlamp housing. THEN carefully remove the lens and bulb assembly and if installed squeeze the two external tabs and remove the wire connector at the back of the headlamp bulb. THEN remove the lens and bulb assembly from the vehicle. THEN remove the rubber boot at the back of the lens and pushing down on the wire loops free their ends from the slots on the lens insert and swing the wire form out of the way.


To Align the headlight:

First verify that the bike has the correct front and rear tire inflation pressure and put the bike on a level surface in an a location with minimum light and point the front of the bike towards a screen or wall which is 25 feet (7.62 m) from where the patch of the front tire contacts the surface which would necessarily be directly below the front axle.
With a horizontal line drawn on the screen or wall precisely at the same height above the floor as the centre of the headlamp and a person with roughly the same weight as that of the principal rider sitting on the seat of the bike to compress the suspension the same as t would be with the rider on the bike and with the bike in a fully upright position similar to the position it would be if being ridden straight ahead, (i.e. with both tires on the floor) and the front wheel pointed straight ahead at the screen or wall, turn the Ignition/Light Key Switch to IGNITION, set the Light Switch on the left handlebar to High beam and check the light beam against the screen or wall for the correct height alignment. The centre of the main light beam should be even with the horizontal line on the screen or wall and be pointed directly ahead so that there is an equal amount of light beam to the left and to the right of the centre mark on the screen or wall. (this would be the lateral alignment).
If the alignment is not correct it can be adjusted without removing the headlamp door chrome ring by using slots placed into the headlamp door through which a Phillips screw driver can be inserted (between the headlamp housing and the rubber gasket). By turning the vertical adjuster screw as necessary the headlamp can be adjusted vertically (up or down). By turning the horizontal adjuster screw as necessary the headlamp and be adjusted horizontally (left or right).

HEADLAMP (FLTR)
HEADLAMP ASSEMBLY
To Remove:
First remove the outer fairing and windshield and move it aside to a work area and squeeze the two external tabs to disconnect the headlamp harness connectors from the bulb contacts. THEN after wrapping some electrical tape around the blade of a screwdriver (to prevent damage to tabs of the transparent lens cover), from the inboard side of the outer fairing, release the top of the transparent lens cover from the slots in the fairing by gently
depressing the two tabs with the blade of the screwdriver. THEN depress the bottom two tabs and remove the lens cover from the fairing. THEN depress the mounting clips on the three hex adjuster studs and pull the headlamp assembly out from the front of the outer fairing.

To Install:
First align the hex adjuster studs with the plastic bosses on the inboard side of the outer fairing and push the headlamp assembly into position in the outer fairing until the mounting clips engage their bosses. THEN carefully snap the bottom tabs of the transparent lens cover into the bottom slots of the outer fairing and carefully snap the upper tabs of the lens cover into the upper slots of the outer fairing. THEN install the headlamp harness connectors onto the headlamp bulb contacts, install the outer fairing and windshield back onto the bike.

HEADLAMP BULB REPLACEMENT
The headlamp is not a sealed beam element but a replaceable Halogen gas filled Quartz bulb. It is filled with halogen gas under pressure and it is fragile so be careful not to break it as gas and glass splinters will fly out from it if it is broken. Also do not touch the bulb with your bare hands/fingers as this will etch the surface and cause early bulb failure. Also because use of a bulb that is not of the rated wattage could cause charging system problems always use only the correct wattage bulb.

To Remove:
First remove the outer fairing and windshield. THEN move the outer fairing assembly to your chosen work area.
THEN squeeze the two external tabs to disconnect the headlamp harness connector from the headlamp bulb contacts, remove the rubber boot at the back of the headlamp bulb housing, rotate the plastic retainer in a counter-clockwise direction to remove from the headlamp bulb housing flange and remove the headlamp bulb.


To Re-Install:C
AUTION
First install the headlamp bulb into the headlamp bulb housing orient it so that the wider ear on the backplate is topside and then push the bottom of the backplate so that the tabs on the outboard side fit snugly into the slot of bulb housing. THEN place the plastic retainer over the bulb housing flange and rotate it in a clockwise direction until it is tight. THEN install the rubber boot over the retainer until it is flush with the base of the bulb socket, connect the headlamp harness connector to the headlamp bulb contacts install the outer fairing and windshield.
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Things You'll Need:
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