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Electrical Issue call 911

Discussion in 'XJ Technical Chat' started by patmac6075, May 23, 2014.

  1. patmac6075

    patmac6075 Active Member

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    If you check the photos below, you'll see the second from the bottom (10a Headlight) connector is burnt, but the fuse is still good...also headlight works fine? This is new to this season...previous work I'd done over the winter was clean horn button (had replaced horns last year, but they just buzzed and would blow a fuse...not sure if it was this one...anyhow..horns work great now), I also replaced all dash lights with LED's...turn signals work, neutral light, brights also work, but the gauge lights never worked (that's what I'm "fixing" right now, when I took off the seat I noticed it. Anyway, I thought since the LED's I bought for the gauges are polarized, I thought I'd spin them 180 and maybe they'd work...but then I notice the burnt connectors...
    Any help is appreciated.
    Pat
    [​IMG]
    [​IMG]
     
    patmac6075, May 23, 2014
    #1
  2. BaldWonder

    BaldWonder Innocent Bystander

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    My best guess is that there must be crud right there in that connector. Perhaps a spider crawled in and made a nest? Maybe it corroded enough to offer just enough resistance to heat it up right there?

    I think your best best is to check every connection (at least for the headlight circuit if not the whole bike) and brush everything clean of corrosion and dirt/crud/spider webs/etc. Also, replace that burnt connector and cut the end of the wire fresh before putting a new connector on.
     
    BaldWonder, May 23, 2014
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  3. Andyam6

    Andyam6 Member

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    If it's getting hot there is an electrical resistance there so BaldWonder is right on the money = bad connection
     
    Andyam6, May 23, 2014
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  4. adrian1

    adrian1 Active Member

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    Correct wattage in headlight bulb? Place finger on terminal and turn headlight on, what happens? Hopefully you have fast reflexes :)
     
    adrian1, May 23, 2014
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  5. Greenbike

    Greenbike Member

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    I think that you should also check to make sure that there is a good contact in the fuse holder. I'm not sure from the photo, but you might be able to swap components around to fix it. I had to replace my old fuse box, the sort that uses round glass fuses, because the fuse clips had lost their spring; two were fractured so I replaced the lot with the blade type that you have.

    It's likely that the headlight has slowly become less and less bright and you haven't noticed. The bad connection has lost you some voltage.

    Power is in proportion to the square of the voltage, so if you lose from your headlight feed 1 volt from 14.5 (typical charging/running voltage) 13.5/14.5= 0.93, square it, 0.93x0.93=0.86, times your power, say 60w, so 60x0.86=52w 8O
    All figures are rounded.
     
    Greenbike, May 24, 2014
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