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FJR Motorcycle Forums
Technical & Mechanical Problems
Lost the headlights this morning 07 FJR
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<blockquote data-quote="Fred W" data-source="post: 1218149" data-attributes="member: 3828"><p>That is "Coupler 5". The green wire that is scorched is the wire that runs 12V power from the output side of the headlight on/off relay to the headlight dimmer (high/low) relay. The only things that wire should be powering would be the two headlights and the high beam indicator in the instrument cluster. (unless someone tapped into one of the headlight wires for some added farkles?)</p><p></p><p>The reason that connector would over heat is either the load (current) through the pin was excessive for the contact area, or the contact's resistance was too high, resulting in excessive heat at the normal load current. On high beams (worst case) you would be drawing just over 110 Watts of power to the headlights, so about 8 amps of current running through that little contact. That is why people advise never just tapping into these wires for added lighting or other farkles. The connectors are already carrying a lot of current for their pin sizes.</p><p></p><p>Using a bypass wire, as previously described by mcatrophy, would seem to be the <em>most reliable </em>way to fix this. You could add an electrical connector in your bypass wire to retain the ability to disconnect the connection, should the need arise, but that would be adding another potential future failure point, and honestly the need to disconnect is pretty unlikely. Probably better off just keeping it simple and soldering the wire around the connector like already advised.</p></blockquote><p></p>
[QUOTE="Fred W, post: 1218149, member: 3828"] That is "Coupler 5". The green wire that is scorched is the wire that runs 12V power from the output side of the headlight on/off relay to the headlight dimmer (high/low) relay. The only things that wire should be powering would be the two headlights and the high beam indicator in the instrument cluster. (unless someone tapped into one of the headlight wires for some added farkles?) The reason that connector would over heat is either the load (current) through the pin was excessive for the contact area, or the contact's resistance was too high, resulting in excessive heat at the normal load current. On high beams (worst case) you would be drawing just over 110 Watts of power to the headlights, so about 8 amps of current running through that little contact. That is why people advise never just tapping into these wires for added lighting or other farkles. The connectors are already carrying a lot of current for their pin sizes. Using a bypass wire, as previously described by mcatrophy, would seem to be the [I]most reliable [/I]way to fix this. You could add an electrical connector in your bypass wire to retain the ability to disconnect the connection, should the need arise, but that would be adding another potential future failure point, and honestly the need to disconnect is pretty unlikely. Probably better off just keeping it simple and soldering the wire around the connector like already advised. [/QUOTE]
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FJR Motorcycle Forums
Technical & Mechanical Problems
Lost the headlights this morning 07 FJR
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