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Discussion Starter #1
I am on my second headlights and for some reason the high beam side always melts! When I take it apart the actual connector to the bulb is melted on.
I never have an issue with the other side, until recently. I checked that bulb as well and the connector is starting to melt on the bulb. That light still works, but I don’t wish to chance it.
I do work on my own bike and sometimes get help from others, but if I can just educate myself and do it. I will. So if describing to me. Please be some kind of specific so if I don’t understand I can research it, or get an idea and have a better way of looking.

Anyways, I read some other forums as I see headlights are a common thing. However, the plugs on the harness which attach to the other harness is fine (right side). I don’t see any visible burnt up wires and everything else works. It’s just the high beam won’t work. But it is melted.
I have never posted so hopefully the pictures work. But if you have any ideas let me know.
My friend and grandfather are electricians so if need be I can have them check currents or whatever for whatever is proposed.

I slightly suspect the relay, but idk where this is. I thought it was the relay on the left side by the fuse box, but was told this was for fans. How do I check to confirm or deny this theory?

Thanks in advance!
 

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Melted connectors are usually a result of corrosion. That headlamp though... that's just not natural. If it was stored, something may have gotten in it.

Cut off and replace that connector. Solder the wire. Do not crimp, twist or cap.

Replace the bulb.

Make sure that there isn't anything "extra" installed, like a ballast or something.
 

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Discussion Starter #4
Yea so this has happened twice with these same headlights. So I plan on buying them yet again. I did do electrical tests and everything tests fine. So I bought new connectors and bulbs. I plan to rewire the new headlights and see if this happens again. If it does then I truly am not sure. I may have to strip the bike and trace all the wires everywhere.

I am starting to really think this the headlights like the whole thing itself. Because it has happened twice but only with these. I’ll update after the parts come in and I swap.
 

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lol wtf. those are plastic lenses? stock lenses are glass. a few guys had cracked lenses but never melted lenses. stop buying china stuff on ebay man. this whole problem is the cheap ****ing ebay headlight.
 

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It never even occurred to me that those were plastic. I had assumed some animal or wasps built something in there. Wow... FleaBay strikes again. I had wondered why those lamps went from $300 and scarcely available to all over the place for $60-$110. Guess that explains it...
 

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also the stock projector housing is aluminum. I have a few left over from a few crashes lol if yours is a oem light then I apologize but it doesn't look like one in those pics and they did not have those problems. you are literally the first I've seen and I've been on 3 R6 forums since 2003. the only real problem was cracked glass. like this one,
 

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Just an update... I bought new headlights... didn't get all fancy just to see how it would work and what not and haven't had any trouble since. I am starting to think it was just that headlight in general. Because I bought two of the same after two accidents and they both did it. So Im good until I buy a better one. I appreciate all of your comments as now I am open to more ideas when fixing my bike again. Which is a lot. lol
Oh side note, I was told that riding all the time with the high beams can make the lights too hot as well. So I stopped doing this except for at night. Could this be an additive reason?
 

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So called high beam and low beams use the exact same light bulb, under the same 12v output, under the same conditions. What turns the "high" beam into a "low" beam, is simply the addition of a block-off plate behind the lense. So your high beam is simply missing that block off plate. In short, they run the same temperature. Run them all the time... doesn't matter. I have the top part of my high beam masked-off, allowing me to run them at night also.
 
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