Im having headlight issues, last month i fix my light cutting in and out and now last night my light didnt come on and then the highs didnt work. I came to find out at a buddies house that my connector on the back of the bulb was melting where the ground wire is. So im just wondering if that will mean I have a bad ground or what. Oh yeah this is on an 02 sportster 1200 custom. If anyone can help me that would be awesome. Thanks

 

bad ground is what happend to my softail it did the same thing

 

cool thanks man

 

In general, any connection that heats up is due to faulty contact. The heat is generated because of the resistance in the circuit the bad connection presents. Resistance means a voltage drop and voltage drop across resistnce creats heat. The extreme case is a direct short to ground which will cause your wiring to melt. This can happen on both the positive and negative connections and many times manifests itself by whatever is in the circuit acting funky. In your case I would have expected your headlight to be dimmer than usual because of the poor connection.

Crazie Dave

 

I figured it out i think. It was the connector in the back of the headlamp itself in the harness. the connector had a gap in it so it wasnt getting a good connection so i just squeezed them together so they touch i think that will help hopefully. If not i guess ill be back with more questions cuz Im not the sharpes knife in the drawer with electricity.

Thanks for the input guys.