Wire Plus and headlamp

[Keith S]

Looking for some insight and ideas. I have a 2004 Chopper with one of the first wire-plus modules. It has performed flawlessly. The bike is in the shop for some work. It has been there for a LONG time (different story). Anyway, I THOUGHT I was FINALLY going to pick it up today. I get there and he tells me the headlight is only shining on the low beam. Bulb is good, but the plug is melted. He can get voltage from the high beam wires, but not the low beam.

I am trying to figure out why the plug melted when it has been flawless for a long time. I am also trying to remember if the Wire Plus combines the high and low beam wires and regulates with voltage.

I am NOT paying this guy to go chasing down wire. I have waited too long and paid enough for the work already.

Any ideas would be appreciated - otherwise, I am just going to start rewiring from the headlamp back:bang::bang::bang::bang:

 

[oldmutt]

When I did the wire-plus on my 08 mutt the high and low beam power was two different wires. The handle bar switch wires are joined so if you press either one the light will cycle high low high low high low. And the melted socket was common back then.

 

[erldawg]

:iagree:

If you perform a search I believe you will find that the melting plug was a common failure. I would suggest changing to a ceramic plug.

 

[wyatt580]

X2 I see them on ebay

 

[Brew]

Yep Ebay: NEW UPDATED BIG DOG HEADLIGHT HARNESS K-9 MASTIFF WOLF | eBay

 

[bdmridgeback]

2004-05 recall for the headlight plug failure. BDM bought plugs made out of too low of temp plastic and they failed terribly.

Yours obviously never had the recall done on it.

Most bikes in 04-05 that have not had the recall done, are riding around with a melted plug in the bucket and the owner just doesn't know it until the plug melts just enough for the bulb to go out and stop working.

Very common, not the wire plus fault.

 

[Keith S]

Sorry if that came out wrong. I was not implying the WP had anything to do with the melted plug. I was trying to find out if the WP module did something to the low/high beam circuits. I vaguely remembered cutting a wire and folding it back into the harness, but could not remember what that was for.

 

[bdmridgeback]

Sorry if that came out wrong. I was not implying the WP had anything to do with the melted plug. I was trying to find out if the WP module did something to the low/high beam circuits. I vaguely remembered cutting a wire and folding it back into the harness, but could not remember what that was for.

That wire was the old ignition switch wire probably.