Headlight Wiring Help

From the 2013 factory service manual

There is an electrical cable that runs from the bike's main electrical harness to a 4 wire connector in the headlight area. This connector carries power for the two headlights and the small "position" light.
The aftermarket installation probably plugs into this connector or crimps to its wires.

This factory cable has the following colors
green = ground (goes to all three bulb sockets)
blue = high beam
white = low beam
pink/blue = position light

The blue wire goes back to the headlight relay and the high-beam dash light.

The factory headlight relay does not disconnect the low beam when it activates the high beam.
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If you know the model and brand of the headlight conversion, perhaps someone else has used it and can offer specific advice.

Since a wire melted, check the rating of the physical fuse in the fuse box. Someone may have installed a way-too-big rated fuse to "fix" occasional fuse blowing due to the bad wiring you mention.

vt500 said:

From the 2013 factory service manual

There is an electrical cable that runs from the bike's main electrical harness to a 4 wire connector in the headlight area. This connector carries power for the two headlights and the small "position" light.
The aftermarket installation probably plugs into this connector or crimps to its wires.

This factory cable has the following colors
green = ground (goes to all three bulb sockets)
blue = high beam
white = low beam
pink/blue = position light

The blue wire goes back to the headlight relay and the high-beam dash light.

The factory headlight relay does not disconnect the low beam when it activates the high beam.
-----------------------------

If you know the model and brand of the headlight conversion, perhaps someone else has used it and can offer specific advice.

Since a wire melted, check the rating of the physical fuse in the fuse box. Someone may have installed a way-too-big rated fuse to "fix" occasional fuse blowing due to the bad wiring you mention.

Click to expand...

Thanks for the reply, looking at the wiring diagram I guess the 3 wires on both headlights are aftermarket, got me so confused since the diagram only shows 2 on each light… I’ve also heard that the h4 bulbs are dual filament and not sure how that would affect the low and high beams, before the headlights stopped working low beam would always be on and headlight+lows would both be on when highbeams engaged (like most motorcycle :0) along with that I was wondering what one random wire was doing (no power going through it either) might be my position light that he disconnected

I double checked the fuses like you said and the only thing changed was my taillight fuse which are 15a instead of 7.5a which sounds fine since it’s got aftermarket tail tidy and previously no issues there just my headlight area.

jdock said:

A ground plug usually does not melt since the power is on the positive/battery plug.
Maybe the bulb gets to hot. Do I understand this is NOT the factory setup?
And when you say you only need high beam , I suggest you rethink that.
Both low and high beams are useful.
And since you're there do it right.

Click to expand...

Thanks for the reply,,
sorry worded it terribly, I meant the wires for the highbeam, before it stopped working there were 3 wires (low, high and ground) connected to the 3 prongs H4 bulb x2 (for both headlights) since the highbeam is oinly meant to come on when I flick highbeam switch (which the white wire is), I was wondering whether I need to reconnect the lowbeam as the 2nd prong??

Appeciate the help