dim headlight??????

i noticed my headlight looked dim so i bought new bulb and it is still dim. i noticed the plug was slightly melted. could this be causing the dimness?

 

Hi Steve,

The melting is normally caused by high resistance in the connection so you would be losing energy at that point so this could be the reason for the dim headlight. Check and clean the connection with sand paper, steel wool or something to abrade any corrosion away and give you some bright brass connections.

On the other hand, low voltage will cause more current to be supplied to energise the bulb also, which will cause melting on components not rated for the higher current. So check your voltage to the headlight also, although you'd have more problems than just a dim headlight if your regulator was playing up I reckon.

Hope that helps!

 

Dim Headlight:

Bad/Worn Alternator brushes.

Bad/Original fuse panel.

Bad/Undercharged battery.

Bad/Dirty connector/wires some where (and/or combination of above points).

Melted:
I can't comment.

 

Definitely check your Alternator Brushes.

Just pop-of the Alternator Cover and measure the Brushes.
10mm is the Service Limit.

10mm or less = Replace.

Fuse Panel:
If you have a STOCK Fuse Panel; get rid of it.
IDEALLY, have a New Fuse Panel soldered in.
(May take splicing extensions on to the Stock Harness Circuit wires.

Then, ... there's the Headlight BULB ... itself.
C-H-E-A-P!
Color Temperature: Yellowish-dull.

Substitute a Sylvania SILVERSTAR MC Bulb for the OEM Nightlight.

 

Re: Sylvania Silverstars: Really nice light, really short lifespan.

I've been running them in my car ('08 VW) and get MAYBE 3 or 4 months out of them, even though they are "Guaranteed" to last a year. The manufacturer gave me one set under warranty, but when those 'blinked out' within 4 months they told me to go pack sand, only the original purchase was warrantied.

HELLA all the way. Chacal carries them; I've been running the Hella halogen conversion for over three seasons now, no worries.

I've also switched brands in the car.

Back to the original question: The melted connector body isn't causing anything; it is a symptom of a problem however; you need to clean and closely inspect the contacts in that connector and possibly replace it. Also check the fusebox, and all the other wiring connections in the headlight shell.

 

Is it possible someone put a 100W bulb in there and it melted the plug, and it's dim because of poor power NOW getting to it?

 

More likely corroded contacts overheated and melted the connector.

Exactly what bulb did you put in it?

Did you do anything as far as cleaning/tightening the contacts?

Did you use a dielectric grease?

 

I would at least replace the (all) melted connectors and use solder/heatshrink tubing to put the new ones in. Clean all wire connections, even if they look ok from the outside. Green corrosion can hide in the smallest places...

 

My SILVERSTAR is going-on its 5th year.

I used it, daily, in my 900 and switched it to the Maxim when I put the 900 in storage.
The Max has Daytime Running Light.
Its always on.

The output IS good. You'll light-up Highway Signs you never saw reflect with an OEM Bulb.

((Plus, ... I have cheated the Elevation of the Headlight UP a couple degrees.))

 

it has stock light in it and i bought a new "white" light bulb to put in it so hopefully it would be brighter but no such luck. i have been trying to locate a connector for it so i can replace it but cant find 1 anywhere.

 

Try auto stores for the connectors. Ebay if necessary.

Quick question: Are you checking the headlight brightness with the bike running? Is yes what RPMs? Try opening the choke and run around 3000 (typical minimal RPMs for charging our bikes).

Don't expect full brightness on non-running bike/low rpm especially if battery is not 100%.

 

Decent looking and fairly inexpensive plug:

http://www.amazon.com/3A-Racing-46-9993 ... 197&sr=1-3

I'm kinda surprised you can't find one of those plugs locally.

Also, I agree with Fitz re: Silverstar bulbs. I started using them soon after they were introduced. Loved the output, hated the lifespan. I used to get 6 months or less out of them, and that was in my truck, not a bike. I switched to GE Nighthawks years ago because they were a good bit cheaper, and I found they lasted a lot longer for me. Had good experiences with PIAA's "whiter" bulbs as well, but they can get spendy.