ceramic headlight plug failure

[HMAN]

Has anyone had their ceramic headlight plug get so hot that it melts the insulation on the wires and the rubber insulator? I thought I had the fix, but apparently not. The low beam went out, so I pushed the lens in and it came on....out off, in on, this fascinated me for a few minutes, then I pulled the bucket apart to find a very nasty mess. Looks like I need to replace the plug and figure out how to dissipate some heat? Its always something.....any ideas?

 

[BWG56]

Replace the plug and put in a LED, they don't get as hot.

 

[francoblay1]

Replace the plug and put in a LED, they don't get as hot.

 

[HMAN]

Replace the plug and put in a LED, they don't get as hot.

Tru....gotta replace the plug regardless. Thanks Ker. An LED may do the trick....? I was thinking along the lines of a water cooled bucket.....but that may be a bit much? Hmmm.....

 

[BroadBand]

Tru....gotta replace the plug regardless. Thanks Ker. An LED may do the trick....? I was thinking along the lines of a water cooled bucket.....but that may be a bit much? Hmmm.....

Nitrogen would work.

 

[HMAN]

Problem solved I hope? Ordered a new plug n LED from WSW. IF this doesn't fix it, well, I may be looking to mount a nitrogen tank on the front end!!! Lol.

 

[SKOGDOG]

I had a similar problem a few years ago. Melted the plastic one and burned the coating off the ceramic replacement. I tried everything , even soldered with silver solder and checked all plugs---then one day I dented my headlight bucket, replaced the bucket with stock-type from Ebay, and the problem went away. Musta been a ground somehow--never did figure it out--still have the old headlight bucket too. Since then gone to LED and will never go back....

 

[chubs]

Ride only on rainy days?

 

[cdogg556]

Nitrogen would work.

 

[Mr. Wright]

FYI. the reason for the heat and melted plugs, is the connection isn't tight enough. if the plug doesn't fit tight on the bulb connectors it will create heat, the more heat the looser they get. The LED doesn't draw very much amperage, so you shouldn't have anymore problems.

 

[HMAN]

FYI. the reason for the heat and melted plugs, is the connection isn't tight enough. if the plug doesn't fit tight on the bulb connectors it will create heat, the more heat the looser they get. The LED doesn't draw very much amperage, so you shouldn't have anymore problems.

That's kinda what it looked like to me too....the rubber cap on the back of the headlight assembly seems to keep the plug from completely seating. I hope the LED seats better? I may have to rework the HL assembly too? Its always fun fun fun......