" There was an unused wire with a 1/4" female push on connector "


Was this wire Orange/White Stripe? It's used on HDI models for a "Position" light and is on the ACC circuit.

 

There were actually 2 wires and yeah, one was orange. In fact that's the one that looked like it had been pinched and the insulation was flat and thin.

 

I've had no more issues since insulating the two connectors and one wire that appeared smashed in the headlight housing. I think we can consider this one solved.
I do by the way really like the LED headlight and the LED aux light's are even more incredible. I'm not sure but I suspect they may be a bit painful foroncoming traffic.

 

wrong led in the turn signal you have to get the right one. Check to see if the socket matches the bulb. Some have two connectors and some have one. You might want to compare the new with the old. Just a thought.