Why connectors are important: OR what an overheated Headlight Plug looks like

Energy One
chacha

chacha

Chaff Your EHC!!
Calendar Participant
So, I'm riding to work at 0'fuck'n dark thirty yesterday and I notice my headlight is out. This was not too obvious since I have the "Freak Mod Driving Lights" (See http://www.bigdogbiker.com/forums/how/1099-adding-driving-lights-2004-bulldog.html for details).

So, I switch over to the high beam and continue on my way. I stop for a coffee and a smoke and check out the bike...the low beam comes on fine now! Not being the trusting sort, I continue the day with the highbeam till I get home. Now I'm think'n that at worst the #*&%^$#*&^ EHC has failed (again!) Since this is the same problem I had the week before the EHC failed the first time.

I get home and check the EHC LEDs and sure enough it's indicating a Low Beam Fault....sometimes. I start dicking with the wiring line and yep, if I yank it a certain way, the headlight will momentarily go out. It's right at the headlight bucket, so I go in and this is what I find;




Now, first question is, "Is the bulb too hot?" I don't think so, it's a standard H7 even though I changed the headlamp (See http://www.bigdogbiker.com/forums/technical/280-crud-adjure-headlight.html for deatils)

A close examination of the plug shows it does a pretty poor job of ensuring the tab from the bulb goes into the slot on the connector to the line. It just doesn't hold the sloted (female) connector very well. I suspect that the tab was sitting next too but not in the connector. Bad connection ==> heat! Why was the connection even working? 'Cause I'm a fucking idiot and put dielectric grease on the connector! So I suspect this disapated the heat nicely into the plug which melted.

So what have I learned?

1) BDM used a cheap headlight plug which doesn't fix the connector in place well,
2) Dielectric grease is probably not for headlight plugs,
3) be sure the tab goes INTO the slotted connector for the wire :up:
 
Raywood

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
chacha said:
So, I'm riding to work at 0'fuck'n dark thirty yesterday and I notice my headlight is out. This was not too obvious since I have the "Freak Mod Driving Lights" (See http://www.bigdogbiker.com/forums/how/1099-adding-driving-lights-2004-bulldog.html for details).

So, I switch over to the high beam and continue on my way. I stop for a coffee and a smoke and check out the bike...the low beam comes on fine now! Not being the trusting sort, I continue the day with the highbeam till I get home. Now I'm think'n that at worst the #*&%^$#*&^ EHC has failed (again!) Since this is the same problem I had the week before the EHC failed the first time.

I get home and check the EHC LEDs and sure enough it's indicating a Low Beam Fault....sometimes. I start dicking with the wiring line and yep, if I yank it a certain way, the headlight will momentarily go out. It's right at the headlight bucket, so I go in and this is what I find;

Now, first question is, "Is the bulb too hot?" I don't think so, it's a standard H7 even though I changed the headlamp (See http://www.bigdogbiker.com/forums/technical/280-crud-adjure-headlight.html for deatils)

A close examination of the plug shows it does a pretty poor job of ensuring the tab from the bulb goes into the slot on the connector to the line. It just doesn't hold the sloted (female) connector very well. I suspect that the tab was sitting next too but not in the connector. Bad connection ==> heat! Why was the connection even working? 'Cause I'm a fucking idiot and put dielectric grease on the connector! So I suspect this disapated the heat nicely into the plug which melted.

So what have I learned?

1) BDM used a cheap headlight plug which doesn't fix the connector in place well,
2) Dielectric grease is probably not for headlight plugs,
3) be sure the tab goes INTO the slotted connector for the wire :up:
Click to expand...
There have been several of our members have this problem with melted headlight plugs.

Odd though that I've ridden across Southern Kalifornia and Arizona in over a 110 degree weather and never had a problem yet others have melt downs. Seems it may be related to a grounded wire or something. I would check out the wiring harness carefully especially under the tank to prevent future problems.

:flag:
 
V

Vegas

Well-Known Member
Looks like the terminal may have backet out of the connector and made a poor connection thus overheating. I agree with Ray as well. Check all your headlight wiring carefully. That may be whats eating EHC's.
 
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bdmridgeback

bdmridgeback

Low Down Chop Shop
That headlight design is half ass. For one thing, a ground on 12 volt accessories is supposed to be as short as possible. And if not a lerger gauge wire should be used.

Well in BDM's great design they use a tiny ass, like 18 awg. wire and then not only do they run it all...I said all, the way back to the battery but they make about 20 loops inside the headlight with extra wire!!! What a FU-up!!!

Mine, between the two bikes, has failed twice.

As long as your runing a standard 55/65 watt bulb and not a 85/100 bulb, your OK!

That is a recall item to be replaced but they didn't change the wiring setup for the recall.
 
chucktx

chucktx

Well-Known Member
that connector looks very similliar to the old dimmer switch connectors of the 70's.....when they were on the floor!
 
bdmridgeback

bdmridgeback

Low Down Chop Shop
Same connector. Also same one that came on the headlight of the 1950-1960 cars!! Might be some left over ones, too that they were using up!?
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
Chacha,

I saw that you indicated H7 Bulb! Was that correct for I thought we are supposed to use an H4 bulb. Not even what the difference is other than I do not seem to recall a Hi/Lo H7 before. Was that a mistake by chance?

I do not see what would be the problem with the di-electric grease for it should not pass any more heat that the rest of the socket unless there was as alread a short somewhere.

Maybe just an accumulation of the heat from (was this a standard 55/60W), or not a good connection with the tang like you indicated. Best to just stop at the Auto Parts and get a new socket and wire it in.
 
chacha

chacha

Chaff Your EHC!!
Calendar Participant
Snake wrote;

I saw that you indicated H7 Bulb! Was that correct for I thought we are supposed to use an H4 bulb.
Click to expand...
As usual, you are correct my friend! It is an H4 bulb not an H7. I had they H7 in my head since I just changed one in my truck yesterday! An H7 is only a two pronger...

:up:
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
I thought something didn't sound right, but hell it has been so long since I have dealt with a H7, I could not remember if there were similar or not.

We need to work and think about getting a group together for a day lor two ride here sometime this early spring. It is looking like the nice day or two we had this past week is now going to be back to the crap of how most of the days have been since I got home.

You take care and my best to you and the wife.
 
Old Hippy

Old Hippy

It's 4:20 somewhere
Calendar Participant
Hey Chacha...

chacha said:
So, I'm riding to work at 0'fuck'n dark thirty yesterday and I notice my headlight is out. This was not too obvious since I have the "Freak Mod Driving Lights"
Click to expand...
Hey Chacha.....I missed this thread earlier this year, but to let you in on this, the dealer in Lynchburg VA informed me of a recall on these faulty headlight connectors and they are going to redo mine once I get my repaired gas tank back from Nick.

~~~~~~~~~~~~~~~~~~
 
scubaman15

scubaman15

Well-Known Member
Just order a HID kit from Jake and you will love the added viz and people WILL notice you at night!:up:
 
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