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General Category >> Rubber Side Down! >> Headlight/Horn/Running Lamp Wiring Connector Issue
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Message started by canonball770 on 06/08/16 at 08:35:53

Title: Headlight/Horn/Running Lamp Wiring Connector Issue
Post by canonball770 on 06/08/16 at 08:35:53

I have a 2011 and I experienced this issue where my headlights, horn and running lights stopped working. I should state that I felt I should try to investigate this myself before paying somebody, however, I have no vehicular electrical experience of any kind. (Well, I don't have any electrical experience beyond a potato battery experiment in grade 3...)

I found one post on the site here were a guy had this issue and found a loose connector. Indeed, my issue was caused by what I believe is the same connector. However, the connector itself is not loose (as his was) as when I ziptied it together, it didn't solve the issue. Upon further experimenting, I found that moving the wires around the connector caused it to fail, but no particular movement consistently caused it to fail. I did notice that one side of the connector was getting really hot, like almost too hot to touch, the culprit seeming to be an orange wire. In the absence of a wiring diagram, I thought I'd try and isolate the offending part. As soon as I unplugged the headlight, the wire/connector stopped heating up. The headlight bulb is correct, it's not like the wrong one is in there, drawing too much power.

I then unwrapped some of the electrical tape behind the connector, to see if it was the whole wire that was heating up or just the connector. As the wire didn't get hot, I conclude that the orange wire is maybe loose in the connector.

So my question is, do I have to replace the wiring harness or do these connectors come separately? Has anybody had any issues like this? Is there something else I should be checking?

PS, I've attached photos of the offending connector.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by justin_o_guy2 on 06/08/16 at 08:48:24

Check fuses.
Inspect the connections inside the connector.
A voltmeter is your friend.
Testing on the Ohms position needs to be done without voltage on a wire.
You can test a connector by reading Ohms from one end to the other. Looking for Low ohms.
You can test with power by checking each side of the connector by setting it on D.C. volts, range above twelve, one lead to ground, somewhere on the chassis, the other probe into one wire on one side of the connector, then the same wire on the other side of the connector. If you see an appreciable difference, clean it up.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by youzguyz on 06/08/16 at 08:56:52

Odds are the connector is not making good contact.
Could be mechanical, could be corrosion.
Could be both.

Corrosion: get a GOOD contact cleaner. I recommend Deoxit D5
https://www.amazon.com/Hosa-D5S-6-DeoxIT-Contact-Cleaner/dp/B00006LVEU/ref=sr_1_1?ie=UTF8&qid=1465401470&sr=8-1&keywords=deoxit+d5
Follow the directions EXACTLY. This is expensive stuff, but really good.
You really should try this before having to resort to the next thing:

Mechanical: examine how the two sides of the connectors mate, and try to bend parts of one or the other (or both) so then get a better connection.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by verslagen1 on 06/08/16 at 09:05:54

The problem is a bad connection.
if the 2 connectors don't mate up tightly, it creates resistance, which causes it to heat up.
do this all with the key off.
1st check for corrosion.
2nd is it loose, this is harder to answer. but it's possible to pop out each connector and if you do it right, it will snap back in. usually there's a little leg sticks out and engages with the plastic housing. once you got it out, clean it, give it a little squeeze and check the fit on the other connector.

once it's all cleaned up and working, get some dielectric grease and give all the contacts a light coating to prevent corrosion.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by canonball770 on 06/20/16 at 13:02:09

Thank you everybody for your responses; great advice all around and it was most helpful. The end result was that although everything was in minty shape, one of the connectors had a gap and was arcing. I cleaned it all up and bent the connector so it gets a better connection and the problem has been resolved. Time to ride! Woohoo!

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by justin_o_guy2 on 06/20/16 at 13:07:46

Next time, you Have some experience..

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by Kris01 on 06/20/16 at 16:38:17

There's a thread around here that has a link to a site where you can get replacement connectors and tools to work with the pins in the connectors. I can't find it. Anyone know what I'm talking about?

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by Kris01 on 06/20/16 at 16:39:48

Nevermind. I just Google'd it!

http://cycleterminal.com/

http://vintageconnections.com/

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by batman on 06/20/16 at 18:16:18

I've heard it said that the weakest part of a motorcycle is the electrical system,and it's true.So why do we have connectors? could it possibly be for the easy of the factory in assembly? Plug and play,but in your case, it"s plug and pay! I guess it bothers me to see people pay good money to replace a failed item with one that is subject to fail again . I would cut the connector out and toss it ,solder the wires ,use shrink tube, tape and never worry again! They will be sealed from the moisture that caused your connector to fail. fuses protect your bike ,connectors do nothing but cause heartache.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by canonball770 on 06/20/16 at 18:41:51

Batman, I whole-heartedly agree. I learned some valuable lessons in this. The biggest being, that sometimes a work-around is alright, and restoring something to as it was, is not always necessary. That connector is really only there to facilitate a connection, so in theory, I could replace it with an after different connector, or, you're right, remove it entirely. I think that with a little research (to make sure that longevity of the part and safety aren't compromised,) a hack is completely acceptable.

Title: Re: Headlight/Horn/Running Lamp Wiring Connector I
Post by batman on 06/20/16 at 18:51:24

I don't think replaceing all the connectors is good ,the majors ,like rectifier,brain box, and stater should stay .But the one we're talking about removing isn't a biggy,and the wires still color coded.