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  • Electrical Fun

    So I'm happily riding down the freeway headed to my girlfriends daughters graduation from college. Bike is running fine, the temperature is great. I get into the next town and while behind a car it looks like my headlight is off. I pull over and sure enough nothing. I fiddle with the bright switch, nothing. I check the fuses, all good. I pull the headlight out and check the bulb, fine. Its an hour from dark so I put it all back together and decided to get her home to find out whats wrong.

    I pull the headlight out again and move the wires around and they come on. When I let the wires go they shut off. I pull the plug out and in the photo is what I find.

    1. What would cause this?
    2. What are the plugs and where would I find them?
    3. Do I need a special tool to wire up the plugs?

    Thank you for your help.
    Burned terminals
    Remember. No matter where you go, there you are.

  • #2
    H4 headlight sockets are easy to find. I’d solder in a new one and use shrink tube to insulate the splices.



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    • #3
      How old's the girlfriend & the daughter Any pic's? Of the graduation from college?
      Last edited by roadiemort; 05-15-2018, 11:54 PM. Reason: http://easternbeaver.com/Main/Elec__Products/Connectors/connectors.html

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      • Milkman
        Milkman commented
        Editing a comment
        They’re both old enough. Plenty of pictures of the girlfriend but I had to put those on the “other forum”

    • #4
      That looks like the white connector from the left switch for brights and turns. I know you can get six pin male and female plugs at radio shack, won't be the same as the ones Yamaha uses.

      Comment


      • #5
        Is radio shack still around?

        Comment


        • #6
          Most radio shacks are gone.
          a good electronics parts house should have something, but you will have to cut and strip your wire, install and crimp the new ends, then push those into the connector. Or find salvage yard then cut and splice
          2005 Silverado Midnight Star

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          • #7
            I use this.
            Buy uxcell 2 x H4 9003 Ceramic Wire Wiring Harness Sockets for Car Headlight: Individual Drive Sockets - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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            • #8
              You can get it at any auto parts store. If you are running a high wattage bulb it can cause excessive heat and burn the plug like that over time. That is not at all uncommon.

              Comment


              • #9
                Cycle terminal.com has that 6 pin plug. My headlight plug disintegrated over time and I bought a new ceramic off Amazon with new terminals and just cut away an inch of wire and re-terminated. If you have Yamaha passing lamps that are tapped into the headlight wires, their case grounds can go to shit and create resistance, overloading the current carrying capacity of the pins and causing them to heat up and melt, without generating enough current draw to pop the fuse. In theory, the fuse SHOULD be protecting the circuit from this, but in practice, it’s a delicate balance and the quality of a given contact can lead to excess heat for the plug without an overload value high enough to blow the fuse. Another reason I chunked the passing lights. Those things gave me more trouble in 65K miles than anything else on my bike.


                Wherever you go in life, ride there if at all possible.

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                • #10
                  totaly agree with jd750ace, but that is not a headlight socket, its a switch socket, smaller pins i think by the pic, but overheating causes vary from bad/corroded pins to excess draw from added equipment as jd750ace said
                  Sometimes it takes a whole tank of gas before i can think straight

                  Comment


                  • #11
                    If your passing lights are wired to be on the low beam and are running 55 watt aftermarket replacement bulbs instead of the factory 35 watt halogens, that’ll also over tax the plug.



                    Comment


                    • #12
                      Then that is what my issue is. I have the passing lights wired into the high beam side of the switch for control. I do have the h3 55w bulbs in the passing lights.

                      It also affected the blue plug. Anyone know the name or number of these plugs so I can get the right kind?
                      Remember. No matter where you go, there you are.

                      Comment


                      • #13
                        We make and sell only the highest quality products.

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                        • #14
                          Cycle Terminal - We have Your wiring Needs. OEM Style Japanese Motorcycle Wiring Terminals and Connectors for Yamaha, Kawasaki, Suzuki and Honda Motorcycles, from the 60’s to the 90’s. Motorcycle electric products and accessories, Motorcycle Fuse Box's, Bullet Terminals, Spade Terminals and Connectors, Adhesive lined Dual wall Shrink tube, Headlight Relay Kits, Horn Relay Kits, Auxiliary Lighting Kits, Accessory Relay Kits,and more.

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                          • #15
                            So I fixed it Instead of getting the connnector I just took that part out of the equation by getting a single blade connector for the white and blue plug and bypassed it. Working great. However I am a Schleprock when it comes to automotive stuff. Never can just go right for me so now one of the screws to hold the headlight in stripped and won’t go in. Self tapping screws?
                            Remember. No matter where you go, there you are.

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