Headlight Harness

[dm_gsxr]

My low beam has bailed so I've been using my high beam during the winter just because it's a bit cold to be out there disassembling the bike.

Anyway, I just popped the front off to check it out and there's some corrosion on the holding spring, more in the connector, and the main connector on the back has melted to the main connector (it's three pieces; wiring harness connector, light socket, and light) so I can't remove it. I've checked replacement harnesses and they're running about $30 more or less, $100 at the dealer.

In removing the bits, when I moved the spring, the low beam went on while I was removing the connector. I suspect (I'll check again) that the spring might have connected with the connectors, perhaps by getting some water inside(?) and thereby caused a short which then caused the meltdown.

Much of this is speculation of course based on the evidence. The main problem is that I'd like to identify the problem before putting the connector back together with a new wiring harness.

Pictures in a bit.

Carl

[Justin]

Still waiting on pics

Are you running stuck bulb sizes etc? Dirty connections with a lot of resistance can overheat and melt too.

[dm_gsxr]

Yea, well I did take pictures but haven't put them on my site yet

I do have the slightly brighter light bulb (5%?) but I also have a headlight modulator which runs them from 20% to 80% (I forget the actual range but it's not 100%). I suspect that since I ride in all weather that one of the rain days I rode the bike in had water spray up and cause a short which melted the plugs.

I did replace the harness and plug as well as use some emery paper (used on copper pipes) to clean up the fixture. The first couple of times I had to gently tap the nose piece to get the light back on but it seems to have stayed good from then on. Once we get another warm day I'll open it up and check it again.

Carl

[BillL]

Short circuits generally cause fuses to do what they are supposed to do.  Have you had to change a fuse?

[shil]

The headlight circuit (and the rest of the wiring) in my old 650 is marginal at best.
I intalled a relay kit from Eastern Beaver.
Much better.

[Specter]

The headlight circuit (and the rest of the wiring) in my old 650 is marginal at best.
I intalled a relay kit from Eastern Beaver.
Much better.

+1 on that - The standard headlight wiring on most bikes is so anemic and long that a direct wired circuit with relay makes your headlight 20% brighter.

[dm_gsxr]

Short circuits generally cause fuses to do what they are supposed to do.  Have you had to change a fuse?

Nope. Never had to change one. I'll try to get pics up tonight.

Carl

[dm_gsxr]

While the headlight has worked fine for years, I have had to change it more often than other folks who ride Hayabusa's. But I do tend to ride in odder places

Carl

[02Tac]

 I can speak up for the Eastern Beaver headlight harness kit.  Headlights on teh Gen 2 bandits are weak at best. This is due to the stock witing be way to small.  Insatalled the EB kit and light output just by at least 50%.  I can see almost as far downroad with the low beam now as I could with the high before.  The bulbs last longer also as they are now running in the proper votlage range.

http://www.easternbeaver.com/Main/Products/products.html

[MGoBlue]

+1 on the Eastern Beaver harness. I installed one on my Superhawk. Very high quality stuff and a significant increase in light output. I opted to put a 55/100w bulb in. I seriously give people sunburn w/ high beam.