Plug melted on headlamp

Discussion in 'Sportster Models' started by sportyXL06, Jul 27, 2011.

  1. sportyXL06

    sportyXL06 Member

    60
    16
    0
    Hey guys ! last week I took my bike out for a spin and when I came home and parked it in the garage I noticed an oder of plastic burning . I traced it to the headlamp housing I removed the lamp an discovered that the negative and low beam side of plug where melted any Ideas what may have caused this any input would help thank you
     
  2. HarryB737

    HarryB737 Junior Member

    656
    26
    1
    Usually that's an indicator of a loose connection. I would replace the socket & be sure to use die-electric grease on the new one. If it transfered too much heat to the bulb, it would be wise to change it too.
     
  3. glider

    glider Veteran Member

    25,464
    108
    44
    Like Harry said, a loose connection causes resistance in the circuit which in turn causes heat. Replace the plug and if you reuse the end terminals over again, make sure to give them a little squeeze with pliers to tighten up the connection to the bulb.
     
  4. dbmg

    dbmg Experienced Member

    5,800
    153
    318
    Has bulb been switched out to a brighter bulb???? Like a 85/100. Don't ask me how I know.
     
  5. HDDon

    HDDon Experienced Member Contributor Retired Moderators

    5,456
    133
    196
    I'm with DBMG on this one. Check the bulb. I don't want to say how I know either.
     
  6. sportyXL06

    sportyXL06 Member

    60
    16
    0
    Yes it was changed 2 years ago I was thinking about that Too should I go stock again ?
     
    Last edited: Jul 28, 2011
  7. NEWHD74FAN

    NEWHD74FAN Experienced Member Retired Moderators

    8,176
    98
    16
    The plug smoked because of a bad connection, 12V times 5A = 60W...a lot of power for a small pin, arcing causes less conductive carbon. With that local heating, even 3W in such a tiny spot is HOT...if you have a bathroom nightlight at home, you know what I'm talking about. Use dielectric grease in the pins, but don't get it on the bulb. I recommend replacing that headlight plug and use Glider's replacement bulb...German Auto find. At $13 for a high intensity bulb 80/100W is a great deal.
     
  8. sportyXL06

    sportyXL06 Member

    60
    16
    0
    Thanks guys I will do that I went to harley today and picked up the replacement plug and new connectors I am not going to use the old ones better safe than sorry!!