melted headlight connector....

[corvtt1969]

got on the s2r today and the highbeam light was on, didnt think to much of it cause its done it before and went away, but when i actually went to check it later, the headlight was out. so i figured needed a new bulb(yet funny both would be out...got me thinking) pulled the headlight open and instantly smelt the wonderful odor of burnt electronics. the socket that plugs into the headlight was melted all around the black wire (assuming its ground). now when i took it off and put it back on it worked, so there was no blown fuse and both filaments on the lightbulb were good. im a little concerned a fuse didnt blow as thats the whole point of them and this could have potentially started an electrical fire. anybody ever heard of this problem? possible things to look in to to prevent further damage/inconvenience?

[zooom]

happened to my old 01 M900 when I had a higher wattage bulb in it...after about 6 months it was pretty crunchy and toasty....I ended up figuring out what parts I could use from work to make a pigtail and butt connector it in and used heat shrink  connectors to seal it all...then covered in tape to keep factory looking and put dielectric grease in the connector to act as a heat sink and had no further problems...

[twolanefun]

anybody ever heard of this problem? possible things to look in to to prevent further damage/inconvenience?

Very unusual IMHO. I have taken my headlight off/on many times for track days and never noticed any problems. But I will watch it now that you have mentioned it. - Gene

[Mash]

I had that happen on the output connector from my voltage regulator.  Would have been nasty if the seat had caught on fire.