250R headlight meltdown...

[Downrangecop]

So I'm cleaning up my 85 250r ( the one on the right)
http://i221.photobucket.com/albums/dd304/downrangecop/25.jpg
when I notice the headlight won't unplug. When I finally got it seperated the plugs broke off the lamp itself. One look at the plug itself and this is what I saw...
http://i221.photobucket.com/albums/dd304/downrangecop/155.jpg
http://i221.photobucket.com/albums/dd304/downrangecop/156.jpg

Obviously there was an issue here! I've never seen a connector have a total meltdown like that before. Aside from the obvious damage to the connector, do you think something else could be out of whack? Or was it a total fluke? maybe just a result of the headlight overheating?

Since I love night riding in the dunes, I had to fix it (and fast... I'm riding this weekend). Using that plug was out of the picture, and I wanted to go with something a little different. I found this headlight setup and thought it would look sweet on the R. Let me know what you think.
http://i221.photobucket.com/albums/dd304/downrangecop/158.jpg

It's obviously different than stock, but I like the change. After this summer I'm stripping the bike down to the frame and doing a complete rebuild and the bike will undergo a color change, hence the white plastic. I'm a big fan of updating the look of a classic. Old school meets modern, kind of like a Chip Foose built 250r, you know what I mean? The color combo and graphics idea I have will definitley turn heads once it's done, IMHO. :w00t:

[cattle-dog]

i have seen that on cars many times, it is generaly caused by a dirty connection.

[Downrangecop]

Interesting. The rubber cover was in good shape and it appeared clean to the naked eye, but you never know. That just comes with buying a used vehicle.

[Mosh]

Good possibility someone replaced that OEM bulb with the higher wattage bulb from the 86 and up models .
Or just poor contact will cause overheating at the plug or high resistance in the ground circuit.

FYI..If you want to go back to stock.

Get a headlamp connector for a 87-93 Chevy S-10 pickup headlight bulb, and wire in that new connector. Available at any major parts store for about 6 bucks.
They plug into the OEM bulbs.

[Downrangecop]

The bulb I pulled out was 75 watt. I don't think that was spec for 85.

[TeamGeek6]

thats a common motorcycle problem, especially Honda. the 1980s Goldwings fell apart due to that problem. The connector terminal gets corroded and a little loose from vibration and the current makes it so hot the plastic melts.

No, the fact it was 75 watts wont cause that.

[oldskool83]

i like the old light better.

[beets442]

My 350X was blowing bulbs and voltage regulator(under seat) came unhooked. It pushed to much power to the head lite, after $40 in bulbs I figured it out....Might be worth a try to check it?...Beets

[ceaserthethird]

That light bulb cause this melt down, 75 watts is to much !