So on my ride home last night my headlights low beam went out. Rode home with the high bean no problem. Opened it up today to see this. Any suggestions how to avoid future burnt bulbs or a fire? Whats causing it?
Do they make a better quality plug?

 

What was the wattage of the bulb you were running? 6 Years on my bike and no issue like that.

Drew

 

This happened to me once, I was riding down town, stopped in traffic, Normal Halogen light,
And I can smell the plastic burning at the traffic lights, and see a little of smoke coming out.

Stopped and opened to see the same damage, I pulled it apart then back together again with some electric degrease did not happen since then, but I have an eye on it, if it goes, will be time to put a new one with LED light. probably a full 7" instead of the 5 3/4.

But yeaa my Indy told me it happened to other bikes and he saw it before

 

ck bad grounds, thats what it is unless you're using giant wattage bulb

 

Happened on a buddy's 05 King, but not quite so bad. Replaced the bulb, but apparently that wasnt it, he's keeping an eye on it.

 

All of the above good info..Have seen a loose connection do the same.

 

The wire that shows as burnt appears to have signs of corrosion, that greenish powder on connections surface. A corroded connection barely making contact will overheat enough to melt the plastic socket.

I'd buy a replacement "pigtail" and splice it in to replace that damaged one. A less costly method would be to just replace the terminal connector (lug) by cutting and stripping back the wire and then attaching the terminal lug to a good portion of the wire. I believe you can get terminal lugs at auto supply stores that will seat back into that connector.

 

i have had that problem on my truck in the past but i was running a higher wattage bulb it it also, i replace with heave duty pig-tails that you can get at most auto parts stores, never did it again after. i later switched to H.I.D.s and have no prob still. as far as the pig-tail went i just spliced in to the factory wires, what i dont understand was what was stopping it from happening at the splice points where the factory wires met the bigger gauge wires....but that question faded when it never happened again.

 

If it's a stock wattage bulb most likely a loose connection caused this to happen

 

+1 it looks like all the heat is at the connection. High resistance creates heat. The wires seem to be holding up just fine.