Wiring Woes

mary2al · #1 (**permalink**) 10-17-2008, 04:28 PM

My 96 900 SS SP -- Everything has been working perfectly till last night the headlight went off twice. The fuse box was very hot and the coils were very warm. I had not been riding hard or long. Any ideas?
Thanks,
Al

El Gladiateur · #2 (**permalink**) 10-17-2008, 06:36 PM

Have you checked the regulator an his wiring?

FunkZ · #3 (**permalink**) 10-18-2008, 04:14 PM

Do you have a bulb with a higher watt high beam? Had the same thing happen to mine, was running a 55/100 I believe and it overheated and melted the headlight wiring harness. Had to splice on a new one and went back to the stock bulb.

BrianK · #4 (**permalink**) 03-04-2009, 12:31 AM

FIRST check battery cable connections - clean and tight?

probably not that but it's the very first thing to check. save you a lot of trouble if that's all it is. BTDT.

stefreem · #5 (**permalink**) 03-17-2009, 05:20 AM

Try cleaning your grounds and terminals. Something is drawing a lot of current to make your fuse box get hot. Does your headlight blow the fuse? Is the correct fuse installed? Do your lights get significantly brighter as you rev your engine? If so, it is probably the voltage regulator. Just start probing it all over with a voltmeter looking for the voltage drop. Check out the Haynes maintenance manual. Hope this helps!