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2014 Sportster 1200T: high beam failed a few days ago. Finally got around to purchasing a replacement bulb, only to pull everything apart to find that the plug melted... Anyone else ever have this problem?
2014 Sportster 1200T: high beam failed a few days ago. Finally got around to purchasing a replacement bulb, only to pull everything apart to find that the plug melted... Anyone else ever have this problem?
not me. perhaps a defective connection that resulted in arcing/melting?
Nice 1st post - care to elaborate. Any electrical mods we need to be aware of, is that the OEM headlight?
No electrical mods. At one point I did have a Daymaker installed, and once the glass broke, I re-installed the factory light. The bulb that was sold to me back in September is a Halogen H4 100/55w. Generic type.
Once you have tracked down the reason, H4 plugs are easy to come by and crimp on.
What are those stalk things sticking out? I have fitted a few bulb connectors and never seen that.
**Learning curve, sorry lol...
Those things sticking out are the guts of the bulb itself... A friend and neighbor was kind enough to help me crimp on a new ceramic H4 plug, no more melting!
No electrical mods. At one point I did have a Daymaker installed, and once the glass broke, I re-installed the factory light. The bulb that was sold to me back in September is a Halogen H4 100/55w. Generic type.
That 100/55 halogen is the problem. IIRC, the standard bulb is 60/55 watts. Running the 100w means that the current is nearly doubled, and the higher temperatures melts the stock connector. I used to run a 100/60 H4 and replaced the plug with a insulated metal version designed to carry the higher amps of the 100w bright. Even then the standard wiring started showing signs of overheating so I went up a couple of gauges on the size.
That 100/55 halogen is the problem. IIRC, the standard bulb is 60/55 watts. Running the 100w means that the current is nearly doubled, and the higher temperatures melts the stock connector. I used to run a 100/60 H4 and replaced the plug with a insulated metal version designed to carry the higher amps of the 100w bright. Even then the standard wiring started showing signs of overheating so I went up a couple of gauges on the size.
Had a hunch. Once I called HD to get the bulb type and size that was sold to me, I went to the website of the store I purchased the new bulb from. The new one is 55/60... My wiring also showed the same heat damage, had to be trimmed back fairly significantly.
Last edited by MichelleBacon; Jun 16, 2020 at 08:54 AM.
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Melted headlight plug
