headlight plug melt down

[85801]

any one had experience with the h 4 plug melting on their bikes headlight. the bulb was good but the plug is toast. i have a '96 1100rt.

[RiverRat280]

Did you put a higher watt bulb in? If you put a bulb with a higher wattage then what its rated for the wires will get hot and melt the connector.

[GregFeeler]

Did you put a higher watt bulb in? If you put a bulb with a higher wattage then what its rated for the wires will get hot and melt the connector.


That can happen, also higher wattage blubs can take out a headlight switch. Another thing that can cause a melted plug is a poor connection. If it was loose or dirty - both of which cause high resistance - the heat build up will melt a plastic connection like that. DAMHIK.

[PUDGYPAINTGUY]

This is never a problem with HID bulbs due to the lower wattage...now tickets are a different matter...hehehehe. If you did have a higher wattage bulb in there did you, or are you considering a different relay setup to avoid loading the switch wires? Just a thought. Otherwise how is the grounding for the bulb? Any corroded contacts etc? Poor conductivity can increase heat in any contact area.

[Stuff2C]

Something else to watch out for on higher wattage bulbs is delaminating of the reflector. Don't ask me how I know this. :doh

[85801]

i was using a stock bulb. went on a trip and smelled something for most of the 1400 miles. when i got back, the high beam indicator wouldn't go off. i ended up replacing the plug with a h-4 plug from an auto parts store as bmw would only sell me the entire loom....for $750. the plug i got was $7. i will probably buy and hour of time from the shop when i take it in for my service...just to make sure there isn't something nasty wrong. i wish i was better at wrenching...

[Jasper]

I installed an H1 55w Silverstar Osram and in a matter of seconds, my complete harness was melted. The bill was appx. $2,000. Fortunately my insurance picked up the bill... I can't explain why this happened - either could the dealer.

[kbasa]

Use one of this guy's harnesses: www.easternbeaver.com

It runs power directly to the headlight from your battery and uses the stock connection to operate a relay.