Headlight trouble.

[alphadog]

Anyone cut off there headlight connected and solder the wires to the damn h4 blades??!!! I have been through two ceramic connectors so far. The blades on the bulb are nice and tight in the ceramic connector at first except after the first ride where the heat makes the H4 blades loose. I have tried bending the blades so they fit snug but the connector continues to back off the bulb while riding. E
I went from electrical tape around it (didn't work) to high temp RTV sealant around the rubber boot to the back of the housing and bulb. The last worked for several weeks but now instead of backing off the damn headlight goes on and off with vibrations!!!! Screw it! I'm ready to solder the wires to the blades on the damn bulb!! I'm guessing excessive heat transfer will microwave the bulb to fail prematurely. Any twist lock conversions out there for H4? I am not ready for led conversion due to reading about EHC failures from them. Any help appreciated even smart ass answers welcome!!

 

[pauldeepsea]

you could possibly have a short in one of the wires causing the excessive heat. my stock headlight melted the plastic harness. i ordered a new headlight and wiring harness. worked fine no issues since

 

[alphadog]

Thanks Paul. I may have to chase the wires deeper on this one. It has had excessive heat since day one at the headlight.

 

[Th3InfamousI]

I ordered some cheap ceramic H4 plugs awhile back same thing happened I ordered a little more expensive set and it was better although I think it just happened again. I guess you get what you pay for

 

[KaptinAmerika]

That is an odd issue
I have been selling the H4 ceramic plugs, use the same one on my K9, and haven't heard of that issue.
Try safety wire, shrink tube it first of course and use a piece of rubber where it passes the wires on the connector.

 

[bearman]

I wonder if vibration is the problem instead of heat......

 

[alphadog]

Thanks for the help guys. I just took apart my headlight bucket and found that two of the three wires melted together as they enter the ceramic. I taped them up with electrical tape and put some red RTV 650 degree sealant around them. The blade on one feels like it came loose. I just ordered a HID kit from A and R Motorsports out of Texas. HID low beam. I'll keep you posted on the install when it arrives.

 

[alphadog]

Kap. I soldered the wires and used heat shrink around the connections. I didn't heat shrink the hole length inside the bucket. The headlight glass feels hot. How hot should the glass be if at all? Thanks.

 

[Slider]

You using 55/60w?

 

[KaptinAmerika]

Can't say a definite temperature but they do get hot
WSW is working on a HID kit that only requires 35 watts
HID low beam and xenon high beam
Were pretty confident it will solve the heat problem and not cause problems with the EHC

 

[jimizee028]

Curtis please let us know when this is available...I have the kit from Jake years ago but I am scared to use it in fear of screwing up the EHC...

 

[bearman]

If you use the stock wires to power 2 new relays, and run three new wires for the HID straight from the battery (fused of course), it should keep the EHC safe.

 

[Ray]

I changed my headlight out completely to the Wolf headlight and ( knock on wood) have never had ant issues at all. It is bright at night too. It is or was cheaper than replacing the regular round headlight anyway.

Ray

 

[alphadog]

Jimzee I used a 55/60w bulb same as stock was.
Thanks Kap.

After so much frustration with this headlight I am willing to take a chance with the EHC. If it goes I will put in a PDM or wires plus over the winter.

 

[erldawg]

Does your headlight wiring have the coil on the black wire?

I thought there was a fix for your problem. Drop Andrew (bigdogtech) a PM.

 

[alphadog]

How are you Earl? I changed the headlight connector and did not add the extra coil of black wire. Not sure if that will make difference in heat.

 

[Diesel Dan]

What does that extra length of black wire do thats all coiled up???? I got a new ceramic headlight connector and it said to CUT OFF that xtra coil of wire.......

I did,and soldered up my new connector to the harness,now I got no fucking headlight at all:loony:.......Is there a resistor hidden in that coil of wire:angry::bang:??????

 

[BigDogBro1]

What does that extra length of black wire do thats all coiled up???? I got a new ceramic headlight connector and it said to CUT OFF that xtra coil of wire.......

I did,and soldered up my new connector to the harness,now I got no fucking headlight at all:loony:.......Is there a resistor hidden in that coil of wire:angry::bang:??????

The coil of wire acts as a choke and helps to slow down the amount of instantaneous inrush current thru the EHC electronics headlight power circuit when the headlight is turned ON.

 

[KaptinAmerika]

Yeah okay, if you say so
BS fix idea for a poorly designed EHC

 

[Diesel Dan]

AAAAAAAAaaaaaaaaaaaaaaaa ok........