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Author Topic: Headlight wiring harness burned up  (Read 334 times)

Pauly

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Headlight wiring harness burned up
« on: May 01, 2013, 06:04:11 PM »
Hey guys.   

In the last couple weeks I've dropped a new AGM battery into my G5 and a new set of shoes (avon AM26).  I really couldn't be happier.

But the theres the new issue. Last fall the wires behind the headlight sorta caught fire and melted into a single mass.  I did my best to separate them and worked some magic with heat shrink tubing.  Last weekend our old friend "mr. Corrosion" found his way into the mess an I rode home with no headlight in the dark.

So the question. I'm trying to find new terminals to build a new harness, but I can't find the same size anywhere in town.  Everything is too small.  One bloke sold me a grey plastic connector that fits but is to deep and hits the speedo cable inside the housing.

Oh, should mention I have the 7" headlight in and it's a G5' in green(that makes a diference$

So suggestions as on how to fix this so it's reliable?

Thanks

Paul
2010 G5
'84 Honda VF45

Ducati Scotty

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  • 2010 Teal C5
Re: Headlight wiring harness burned up
« Reply #1 on: May 01, 2013, 06:16:14 PM »
It's tough to fit the one piece connector in there with the 7".  I went back to individual flag terminals.  I wrote the wire colors for each connector on the back of the reflector so I won't forget which is which.
http://www.jameco.com/1/1/1667-19007-0021-250-inch-fully-pre-insulated-quick-disconnect-flag-terminal-14-16-awg.html
The flag style doesn't stick backwards and you can splay the connectors a bit if you need to.  You should be able to find them somewhere locally now that you know what to ask for.

Scott

Pauly

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Re: Headlight wiring harness burned up
« Reply #2 on: May 02, 2013, 09:45:07 PM »
All righty. I had the flag terminals already, they didn't fit. Then some stuff happened with a screwdriver and they did.  Sure looks a lot more clean and reliable. Only time will tell. But it's working now

Thanks a bunch

Paul
2010 G5
'84 Honda VF45

Ducati Scotty

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Re: Headlight wiring harness burned up
« Reply #3 on: May 02, 2013, 10:39:21 PM »
Like most RE installs, just takes some persuasion :)