Resolved: 2001 ZZ4 Boss Hoss Headlight Low Beam not Working

[The Mindless Philosopher]

My 2001 ZZ4 Boss Hoss recently had an issue with the headlight low beam intermittently working, sometimes at startup and sometimes not at all. It would also grow dim and then dark at times. The correctly rated fuse would never blow, indicating no electrical short; and the intermittent operation was a clear sign of no electrical open.

After a little online research, some visual inspections, and some basic tests with the aid of factory Boss Hoss wiring diagrams forwarded to me by another rider on social media, the issue is resolved.

The root cause was a bad ground wire from the black 7-wire harness at the frame neck, up the handlebar and back down to the billet aluminum triple tree. I disconnected the wire from both ends and replaced it with a new ground wire leading directly from the steel frame to the wire harness. Now, the low beam is bright, steady, and reliable.