Headlight failure along a Trek is not a rare problem according to ride reports.
- First the obvious…Carrying a spare headlight bulb and fuses is worth it if that is an option for your system. Many have concluded that the helmet light is also worth the cost/weight for Treks and can serve that purpose as well.
- Use vibration proof and weather protected wiring connections, soldering when possible. Avoid cheap crimping on main power lines. Shield and secure loose wires.
- Heavier gauge and insulated wire helps, but is especially important between the stator and regulator/rectifier box.
- Ensure a solid ground connection at the rectifier/regulator. Clean that frame mounted ground connection and a redundant ground wire to the battery ground is a good idea.
- Setup a running light or always-on low beam to help the regulator work and take off some of the excess stator/regulator heat. Heat is the enemy of your stator, Un-used power comes back to the stator and heats it because most common dirt bike regulators work by looping back extra voltage to the stator AC coils. This mean the impedance of the stator and the regulator are consuming all the unused power in the form of heat. Consuming some power in your headlight takes that away from the stator/regulator loop.
- For the same reasons above, make sure you have good air-flow on your regulator. Roughly half the un-used wattage coming from your stator is converted to heat on your regulator as it loops back the excess.
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