Electrical issues, melted connector contacts

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You're reading: Electrical issues, melted connector contacts

166 posts

discussion starter · #1 · oct 12, 2013

after i fixed the caliper the other day, i went for a test to find the headlight isn’t working at all. the low beams haven’t worked since i got the bike, but now the high beams are out as well. i traced the issue to the biggest 11-pin connector i could find on the wiring harness, on the front left side. it melted on the high beam contact:

http://i.imgur.com/r3rjedx.jpg

i confirmed this as the cause after cutting the wires from the connector and making a direct connection:

http://i.imgur.com/6b08yzv.jpg

now the high beams work again. so i guess this is one way to fix the problem, bypassing the connector and just connecting the wires directly. during my search, i found another connector that must have shorted in the past:

http://i.imgur.com/oio3043.jpg

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the po just cut the wires away from the connector and connected (soldered?) them directly to each other:

http://i.imgur.com/j17lzx8.jpg

so i guess i could do the same thing with the high beam wire and just solder them together directly, but i’d rather do it the right way. from what i understand, the proper fix is to replace the failed connectors entirely.

so if i am right here, i was wondering if anyone could direct me to a vendor who provides the oem connectors, or maybe this is just not feasible? i found a couple options on eastern beaver, namely the 12 position 090 mt connector:

electrical issues, melted connector contacts

would this type of connector be an adequate replacement? also, what should i do to prevent this from happening in the future?

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11,333 posts

here;s another source for connectors

http://www.cycleterminal.com/index.html

question? do you have stock wattage headlight bulbs ? or something a little brighter ? higher wattage bulbs will fry connectors, also make the reflector brittle and thin due, all to to the excess heat that the wiring, connectors & sockets that were designed barely for stock wattage

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166 posts

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discussion starter · #3 · oct 12, 2013

i just pulled the bulbs and they’re rated 100/55w:

http://i.imgur.com/cnpsvqp.jpg

the service manual (for the naked single headlight) says 60/50w. could this be the issue?

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11,333 posts

i just pulled the bulbs and they’re rated 100/55w:

http://i.imgur.com/cnpsvqp.jpg

the service manual (for the naked single headlight) says 60/50w. could this be the issue?

most definitely

Source: https://tonupboys.com
Category: Headlights