I have been having a problem with my headlights burning out almost instantly. I replaced the stator, and i have replaced the regulator, still burning out. Any suggestions??
There are only a few things that will cause an incandescent lamp to fail. Over voltage, faulty wiring, dirty connections, excessive vibration, and air getting into the glass globe.
You have covered 2 of them with a stator and regulator. Did you use new regulator?
It was used, I have 3 regulators, i have tried all 3, everytime the bulb goes...I actually took off all the wiring to whole bike, im gonna re do all connections, and grounds...
your ground wire may be compromised somewhere so you can try running a ground wire to an un-painted area of the frame (drill a hole, use a pop rivit).
You can also put a fuse to match the bulb specs inline of each power line (high/low beam) to see if the fuse pops. This way you save on bulbs and can tell if spikes are killing your bulb.
Measure the voltage at the bulb holder with the bulb removed, with a multimeter. If you are over voltage it will show up there.
Are you using a 12volt globe? Is the globe fitting into the holder properly, and are the contacts clean?
Could the switch be arcing, if so it may fool the regulator into a voltage spike (unusual but it can happen).
Make sure that you have a good ground