Originally Posted by cynicwanderer
the headlight is on it's own AC circuit. it's separate from the turn signal/brake light and ignition. however, I think the blue instrument light, runs form the headlight circuit, but doesn't take much current to run it. if the connector is burned, you might want to check if the AC regulator is working, i.e. hook up a AC voltage meter and check if the voltage goes much above 14VAC when you rev it. higher voltage means more current in the light, and can cook the connector as well. bad/loose electrical connections, will also heat up the connector.
I think it just came loose it was just a $2.99 plug. I just fitted a hi-temp plug on it and the light is working. The plug is much better in quality too. I'm about to take my bike to uncle's so I can test the AC regulator like you suggested.
'83 Honda XL600R 618cc 11:1 Wiseco, XR's Only Exhaust, big tube header, 6 Sigma stage 3 carb mods