Burned headlight Plug and wire on 97 Tour

[dennis_obryan1965@msn.com]

Headlight quit working, bought new ones, disassembled the head light and found the plug that pugs into the bulb had gotten hot and burned , and burned one of the wire off. As you face the bike its the wire that hooks to the left side of the plug. How do I fix this, What may have caused it. As far as I can remember it was a OEM bulb in the headlight.

Thank You

[Daniel Meyer]

A non-stock bulb or a loose/bad connection...both can do this.

You can get a new plug at the autoparts store in the "help" parts section...standard H3 / 9003 bulb plug.

[chrise2469]

Daniel beat me to the punch again-

Link to the old tech archive with a part number for a high temp connector.
http://www.valkyrieforum.com/forum/tech_archive.cgi?read=1049754

If the bulb is a 55/60W its the same wattage as the original. The wire could be a bad connection, corrosion on the terminal etc.

How you splice in the new connector is up to you.

Good luck and ride safe.

[9Ball]

recommend soldering and shrink wrap as a minimum for the new plug.....

[Warlock]

Headlight quit working, bought new ones, disassembled the head light and found the plug that pugs into the bulb had gotten hot and burned , and burned one of the wire off. As you face the bike its the wire that hooks to the left side of the plug. How do I fix this, What may have caused it. As far as I can remember it was a OEM bulb in the headlight.

Thank You

Once you get your plug look here at Chet's site under start switch safeguard
http://www.rattlebars.com/mtz/foglites.html
Very good mod.
David

[Kingbee]

Heree's the High Temp, high current socket available at NAPA