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Old 08-28-2004, 09:46 PM   #1
MTNBRIDER OP
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Eh? Ground wire to headlight melted?

I've noticed the brown wire going into the plug on the headlight getting hot and smelling. Its on a '99 f650. The plug is melting some too. Any ideas why this would happen? Where should I look for a new plug to wire in?
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Old 08-28-2004, 10:05 PM   #2
bigdog99
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Are you running a 55/100W headlight? Typical Beemer wiring is too light to handle the 100W high beam. My R100GS wiring got toasty from above, but I switched back to std 55/60 and haven't had any other problems. You should be able to get a pigtail at any auto parts store if you do need to replace it.
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Old 08-28-2004, 10:48 PM   #3
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I'm not sure which bulb is in mine. I just bought the bike used a couple months ago. Is it written on the bulb if I remove it?
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Old 08-28-2004, 11:17 PM   #4
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Now I have removed the bulb and see that it is a 12v80/60. Do you think that is big enough to cause a problem? Are there any other wiring problems I should be looking for? i.e. ground problems?
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Old 08-29-2004, 02:47 AM   #5
Davey R.
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If the heat dammage is close to the connector it is possibly a poor connector or undersized. If the entire wire is scorched then the wire is undersized. Best bet is to install larger connectors and wire. The problem is ussually not too much voltage (unless regulator is kaput), its amperage. The only way to accomodate greater amps is with larger wire. Good luck, Dave R.
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Old 08-29-2004, 05:11 AM   #6
NJ_Bob
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Quote:
Originally Posted by MTNBRIDER
I've noticed the brown wire going into the plug on the headlight getting hot and smelling. Its on a '99 f650. The plug is melting some too. Any ideas why this would happen? Where should I look for a new plug to wire in?
What you probably can be safe assuming is that the individual connector pins are making a poor connection, and as a result heating up.

You might want to consider splicing those wires together and solder them to eliminate the poor connection.
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Old 08-29-2004, 08:46 AM   #7
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Eh?

Thanks for the help, I'll solder in a new connector today and see if that takes care of the problem. If not, I'll go to a smaller wattage bulb.
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