My lowbeam quit working but the highbeam still works. Pulled the headlight apart and the yellow wire connecter in the plug witch supplies the 12 volts for the lowbeam is all melted ……….AGAIN. The first time I pulled the headlight apart back in Nov to have it powder coated I noticed the plug was melted but the light still worked. I replaced the plug when I reassembled the headlight. This is the second time this has happened and I have already replaced the plug once. Doesn’t seem to have any opens or chaffing in the wire. WTF? Anybody have any ideas and have seen this before?

willyp

 

It could be the bulbs wattage is too high.

 

thanks for the reply, i think it happened the first time with the stock bulb but it still worked, i replaced the plug with a new one from the stealer and the bulb with a PIAA bulb that says "direct replacement for stock bikes using the h4 bulb with the 3 prong base"