Author Topic: Melted another headlight plug  (Read 386 times)

0 Members and 1 Guest are viewing this topic.

Offline crag antler

  • Training Wheels
  • *
  • Posts: 67
  • AREA: Northeast Area
  • COG#: 8277
  • Membership Level: Active
Melted another headlight plug
« on: June 23, 2018, 09:56:17 pm »
So my 2000 Connie with 54 k loved miles has decided to turn off the headlight.
Luckily, it happened close to home during the day. When I pulled everything out, thinking it was the bulb, I noticed the plug melted.
Needless to say, this had happened about 3-4 years ago and I replaced the headlight harness with an E-bay purchase.
Do not know if this is due to my long-term habit of having the headlight switch in the Hi-Lo position where both filaments are on. ;) :))
Went to Murphs and ordered the upgraded headlight harness. Hopefully this will remedy this concern and give me an excuse to purchase driving lights :beerchug:
Just want to make sure this isn't a sign of things to come.
Thanks, Doug
Doug aka crag antler  Florida Cracker in South Conway
2000 Kawasaki Concours
2011 Suzuki DR650

Offline connie_rider

  • "OtP" {retired/assistant} Slave Labor
  • I Need a Life
  • ******
  • Posts: 8005
  • Help us make "OtP" possible! "AGAIN"
  • AREA: South Central Area
  • COG#: 4154
  • Membership Level: Asst. Area Director
Re: Melted another headlight plug
« Reply #1 on: June 23, 2018, 11:30:03 pm »
I don't recall that there is a position where both filament's are on?

I used Murph's harness and added a switch/diode that allowed the occasional use of both filament's.
Bright as heck but a lot of heat at the plug.
I think mine eventually melted the solder in the plug as I also had a higher wattage bulb.
  {replaced the 80/100 with a 100/120)  :-[

With the std wattage, it worked fine.

Ride safe, Ted
« Last Edit: June 25, 2018, 11:08:30 pm by connie_rider »
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

If your not already a COGger, "consider becoming one".
Help us make "OtP" possible again, DO IT NOW!!

Offline crag antler

  • Training Wheels
  • *
  • Posts: 67
  • AREA: Northeast Area
  • COG#: 8277
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #2 on: June 24, 2018, 12:12:03 am »
There is that “sweet” spot on Kawasaki headlight switches in between High and Low where they both will light.
Old trick from my KZ1000 J days. ;)
Guess I’ll just stick with the High beam during the days.
Doug aka crag antler  Florida Cracker in South Conway
2000 Kawasaki Concours
2011 Suzuki DR650

Offline connieklr

  • Street Cruiser
  • ****
  • Posts: 787
  • AREA: Northeast Area
  • COG#: 1608
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #3 on: June 24, 2018, 10:35:23 am »
Fortunately, I never found that “sweet spot.” Running 80/100 bulbs, I did have the OEM lamp socket melt on me a very long time ago and I replaced it with a Bakelite version from NAPA. When fitting it up, it felt loose on the bulb’s prongs so I shored up the back of the contacts with some shim stock to tighten them up and help eliminate any contact resistance….. which will create enough heat to destroy a socket in a heartbeat. That was well over 100K miles ago, and so far, so good.
« Last Edit: June 24, 2018, 11:25:08 am by connieklr »
________________
Guy Young
COG #1608
COG Life Member
Semi-Civilian
GB Young Services, LLC

Offline m in sc

  • Mini Bike
  • **
  • Posts: 171
  • AREA: Southeast Area
  • COG#: Forum
  • Membership Level: Forum Subscriber
Re: Melted another headlight plug
« Reply #4 on: June 24, 2018, 01:27:01 pm »
why would you use both filaments at the same time?!? the harness isn't designed for that load (almost double the designed amperage draw.) just get a good led bulb, way brighter and a lot less load. you're lucky it didnt cause any fires or fry the harness further down the line.








Online MAN OF BLUES

  • I Need a Life
  • ******
  • Posts: 7562
  • AREA: North Central Area
  • COG#: 5977
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #5 on: June 24, 2018, 06:37:31 pm »
Fortunately, I never found that “sweet spot.” Running 80/100 bulbs, I did have the OEM lamp socket melt on me a very long time ago and I replaced it with a Bakelite version from NAPA. When fitting it up, it felt loose on the bulb’s prongs so I shored up the back of the contacts with some shim stock to tighten them up and help eliminate any contact resistance….. which will create enough heat to destroy a socket in a heartbeat. That was well over 100K miles ago, and so far, so good.

I also was a promoter of the NAPA 80/100 bulbs, and can attest they work fine when used in conjunction with that NAPA Bakelite socket, and, I also suggest as you did, some attention be given to the sockets metal guts... even the OEM sockets could stand a periodic inspection...
I didn't add any shim stock, but have stuck a small screwdriver blade in the wire access spots, from the rear, and flexed the actual metal blade connections in the socket to make them fit snugly when the lamp blades are inserted.. even on the OEM socket, THAT is the important junction,  this helps prevent the meltdown, which is common.

30 YEARS OF KAW.....Rich R. (the other one..)  COG 5977  JUSTAMEMBAHNOW
and if you are gonna call me names... it's MR. Analdweeb if you please...

Offline connie_rider

  • "OtP" {retired/assistant} Slave Labor
  • I Need a Life
  • ******
  • Posts: 8005
  • Help us make "OtP" possible! "AGAIN"
  • AREA: South Central Area
  • COG#: 4154
  • Membership Level: Asst. Area Director
Re: Melted another headlight plug
« Reply #6 on: June 25, 2018, 01:25:16 am »
m in sc, when I did mine, the LEDs that were available were not as good as they are now.
Why?: Hi beam lights up out further, but looses the close light.
           Being able to also run the lo, gave you near and far, without the need to hang aux lights on the bike..
            Lights up the world pretty good..

Another why; Because it was something to try, and COGgers like to try different things.

NOTE: I was not putting the increased amperage thru the stock wiring. {probably a No-no primarily because the amperage can take out the switch itself..}
          I added Murph's headlight harness to my bike.
           With it installed; the stock switch and harness only switch Murph's relay {low/hi}.
            Because of that, the stock harness and carries very little load.
                 Murph's harness handled the extra amperage fine.
           To make mine work, I used the aux circuit on his harness, to power the low beam when the hi is selected.
                                         {and added a selector switch and diode}.
           Once installed , you can use your normal switch to select low or hi,
                                   or trip the selector switch and be able to select low or both beams.
            {I suspect this would work with LED's, but imagine the heat would be too high}

Murph's harness came with a Hi Temp plug that worked fine, until I tried "even" more wattage..
Even then, it didn't melt, the solder did... {gloom}

Ride safe, Ted
« Last Edit: June 25, 2018, 02:38:24 pm by connie_rider »
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

If your not already a COGger, "consider becoming one".
Help us make "OtP" possible again, DO IT NOW!!

Offline RWulf

  • Crotch Rocket
  • ****
  • Posts: 1638
  • AREA: North Central Area
  • COG#: 7122
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #7 on: June 25, 2018, 01:00:50 pm »
Did the extra heat have any effect on the headlight reflector?

Offline crag antler

  • Training Wheels
  • *
  • Posts: 67
  • AREA: Northeast Area
  • COG#: 8277
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #8 on: June 25, 2018, 01:13:10 pm »
I'll honestly have to look.
Good thought. :motonoises:
Doug aka crag antler  Florida Cracker in South Conway
2000 Kawasaki Concours
2011 Suzuki DR650

Offline m in sc

  • Mini Bike
  • **
  • Posts: 171
  • AREA: Southeast Area
  • COG#: Forum
  • Membership Level: Forum Subscriber
Re: Melted another headlight plug
« Reply #9 on: June 25, 2018, 01:45:06 pm »
i get that, but  times have changed for sure. Only halogens i currently run are in the 3 ac lighting bikes i have

even if ones bad out of the box (rare, i have had one die), this still works great. i have zero visibility issue with these. and, its just easier on the charging system by a long shot.

https://www.ebay.com/itm/H4-HB2-9003-980W-147000LM-CREE-COB-LED-Headlight-Kit-High-Low-6000K-Bulbs-Power-/263588030843?_trksid=p2385738.m4383.l4275.c10

the insert can be installed 180 out, its a twist and lock. so check before installation. 


Offline connie_rider

  • "OtP" {retired/assistant} Slave Labor
  • I Need a Life
  • ******
  • Posts: 8005
  • Help us make "OtP" possible! "AGAIN"
  • AREA: South Central Area
  • COG#: 4154
  • Membership Level: Asst. Area Director
Re: Melted another headlight plug
« Reply #10 on: June 25, 2018, 02:19:14 pm »
Thanx; That is the least expensive LED's I've seen. I think most have been using the Evitek's with good luck.

On the Cree's you posted, it's interesting that their doing exactly what crag antler and I did.
Their using "all" the filaments/LED's when it is on high beam.

Ride safe, Ted
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

If your not already a COGger, "consider becoming one".
Help us make "OtP" possible again, DO IT NOW!!

Offline m in sc

  • Mini Bike
  • **
  • Posts: 171
  • AREA: Southeast Area
  • COG#: Forum
  • Membership Level: Forum Subscriber
Re: Melted another headlight plug
« Reply #11 on: June 25, 2018, 02:30:02 pm »
thats why i listed it. and it has much less draw on the whole system.   :beerchug:

Offline crag antler

  • Training Wheels
  • *
  • Posts: 67
  • AREA: Northeast Area
  • COG#: 8277
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #12 on: June 29, 2018, 02:19:59 pm »
i get that, but  times have changed for sure. Only halogens i currently run are in the 3 ac lighting bikes i have

even if ones bad out of the box (rare, i have had one die), this still works great. i have zero visibility issue with these. and, its just easier on the charging system by a long shot.

https://www.ebay.com/itm/H4-HB2-9003-980W-147000LM-CREE-COB-LED-Headlight-Kit-High-Low-6000K-Bulbs-Power-/263588030843?_trksid=p2385738.m4383.l4275.c10

the insert can be installed 180 out, its a twist and lock. so check before installation.

Thanks :-[ :-[
Now I went and bought those also. :great:
The harness, this bulb and my LED driving lights, I should be so much brighter.
The bike, that is. :))

Stupid question, for the install, what is the easiest way to ensure its proper?
First time LED headlight bulb install.
Doug aka crag antler  Florida Cracker in South Conway
2000 Kawasaki Concours
2011 Suzuki DR650

Offline connie_rider

  • "OtP" {retired/assistant} Slave Labor
  • I Need a Life
  • ******
  • Posts: 8005
  • Help us make "OtP" possible! "AGAIN"
  • AREA: South Central Area
  • COG#: 4154
  • Membership Level: Asst. Area Director
Re: Melted another headlight plug
« Reply #13 on: June 29, 2018, 03:12:38 pm »
Assuming you bought the ones with 3 LED's, I think you install them with the 1 (hi beam) LED "down"??

Someone, please advise me if I am incorrect? {again}

Ride safe, Ted

PS: In this discussion it has been mentioned that some made efforts to tighten the connection at the plug.
      I'll agree that is a help, but most of the heat that melts the plug, is from the bulb/filaments..
« Last Edit: July 03, 2018, 12:41:31 am by connie_rider »
14 Connie (Traveler II) / 03 Connie (Buddy)
Gone but not forgotten; 87 and 00 Connies..

If your not already a COGger, "consider becoming one".
Help us make "OtP" possible again, DO IT NOW!!

Offline Steve

  • Tricycle
  • Posts: 12
  • AREA: Northeast Area
  • COG#: 12718
  • Membership Level: Active
Re: Melted another headlight plug
« Reply #14 on: June 29, 2018, 04:24:36 pm »
My oem headlight bub finally gave out after 25 years (1993) and I upgraded to an led unit with a cooling motor attached. The oem plug/connection was a perfect fit and the led unit has no clearance issues. Install, twist to secure, connect and go. It lit up the road very well on a 2am ride home from Laconia 2 weeks ago...