I am having issues with my headlight on my 95 FLHTP. It appeared like it was burnt out so I took it off to replace the bulb. The plug was melted. I checked and had continuity from the frame to all 3 wires. I remembered discovering the Hi/Lo switch in between positions while I was riding last week. Is it possible for that to cause this problem and what did it do? Burn the switch up? Melt wires together? I really would rather not take the fairing completely apart if I can avoid it. Any help would be appreciated. Thanks

 

you can get an upgraded plug at pep boys which will better handle the heat.

If you had the in between position in use, that equals more heat.

replace the plug ( the obvious damage) and start over.

Mike

 

I bought a new plug but considering I have continuity between the frame and all wires to the h/l, it tells me there is a short. I'm wondering why this wouldn't have blown a fuse.

 

Update: cut old plug off and installed new plug. Headlight appears to work on low. When I switch to hi, instead of shutting the driving lights off, it just dims those while turning the h/l on hi.

 

what happens with the spot light switch in the off position ?

ah, cop bike I don't think I have a wiring diagram for the cop bike ( and often stuff is just cut off when taken out of service)

- Um IS there a spot light switch or are the lights wired to the "pursuit"

Mike

 

Sorry, I should have mentioned, this was never used as a police bike. I purchased new from the dealer.

 

With the spot light switch in the off position, everything seems ok just sitting there. Traced every wire for the headlight and spotlights. Tried bypassing the hi/lo switch. Tried a new toggle switch for the spotlights. Tried hooking ground from headlight to frame.