I had replaced the OEM headlight bulb and had it running for about a year now! Last 2 months was having a dimming of the bulb, then really bright. High beam indicator on dash would come on also. This would come and go! It looked like I had a short. Had replaced the bars,controls, and extended the wiring earlier. Thought that might be the problem area...

Bulb finally burned out, and when I took apart the assembly to replace it...The harness connector that the bulb plugs into was melted

I replaced the connector and put the OEM bulb back in, and it seems o.k.

Anybody run into any issues with the Sylvania Silver Stars?? Same rated voltage/watts...but must run a-lot hotter!!

 

A loose connector can create a lot of heat.

 

sure thang if it was loose creates more resistance and resistance creates heat such as corrosion on a battery creates alot of heat as well.

 

I can relate to that,...but I am kinda sure the connector wasn't loose!! I don't want to attempt the Sylvania SS replacement If it will happen again!!

 

well i know for my car i put in bulbs of that nature and had to get new connectors bc the plasic did meltify if you know what i mean now i have metal connectors for my car i bought off of ebay.

 

I put a Silverstar in place of the original bulb on my 08 FatBoy. Lasted about 3 months or so before burning out. It really wasn't much brighter than the factory bulb so I put that back in. Amp draw was close to stock so there was no wiring problem for me, just poor bulb life.

 

I had a similar problem and solved it by putting in a ceramic connector from Eastern Beaver (Yeah I know strange name but good parts and info therein)

The problem was and is always at the connector. Sometimes the wires will get hot if they are very old or degraded, but that problem can be fixed by adding the relays HD should have put in at the factory if the new connector just moves the problem to the wire.

Eastern beaver also has a discussion on headlights that is well worth the read.

http://easternbeaver.com/Main/Elec__...onnectors.html