Yep, you’re correct about the headlight (after a time) over heating the connector (even on a stock setup) and being a BIA to deal with. Even putting dielectric grease on the connections doesn’t always help. I’v destroyed two bulbs trying to remove my faring and disconnecting the headlight.
As posted, check that you’re running the correct bulb in your headlight. A higher wattage bulb, while it may work and give you more light, will overheat the connector faster than a stock one.
Are you running it on Bright? If so you’re pulling the maximum amps and overheating the connector. This is something that doesn’t happen overnight just over time. The fact that your “blowing / tripping” the breaker is an indication that your pulling over the maximum Amps for that circuit.
Check the manual or ask at the dealer what the Amp rating for the circuit is.
(Voltage x Amps = watts)

 

I think it has been dancing on the threshold of maximum because the fuse doesn't blow right away. It usually takes it several days. I have been running with my spots off for a while but now that I have removed the module I am running them again to see what happens.

 

I went by the dealer at lunch and verified that I do have the correct module for my bike. Not really sure why it did what it did but at this point it is off and I am going to look at other choices because I am not completely trusting of this one now. I like that it bugs people because that means they see me but when I am blowing fuses that is not such a good thing. So far I have been running with the spots on again and am ok but it did fine for several days at a shot so I am not completely convinced that there is not a problem.

 

If it is intermittent, I suspect a bad connection (short) someplace in the wiring.

 

That is something that I will be looking for. It would not be the first thing on this bike that I have found loose either. I had a problem with the speed sensor and so I replaced it and the wire got in an odd spot and rubbed through. I spent some time last night inspecting wires and adding some cable ties in spots to secure everything under the fairing better. Wires hanging loose is not only sloppy its down right dangerous.

 

Naysayers can F-off. The fact you don't like them shows they work EXTREMELY well. If it's "your time" why not wear a POS helmet and no seat belt when driving?

In fact, haters of loud exhaust say the exact same thing.

OP: Did you get the unit sold by HD? They have one now, so far, so good with mine.

 

Yes I it was the HD unit. I found out that because I got it last year it only had a 90 day warranty on it and that as of January they now have a 1 year warranty. Go figure!It was out of warranty by the time I started having trouble with it...

I am +1 with you on the whole thing. The light modulator has gotten a lot of comments, which tells me I get noticed more, and it has even caused some people to move over a lane for me, maybe because they think I'm a LEO, IDK but if they want to move over I will go by

I rock my music loud and proud and as soon as I can afford a new TD exhaust system I will do that and make it loud and proud that way as well. I need to get new speaker too because I have blown the left front

In the mean time I am checking all my connections and looking for loose wires as well as securing everything with new cable ties. The thing I am concerned with are shorts and grounds. I had to replace the stater over the winter and found that the pig tail from the old one had bare spots in it too. I suspect that the damage to the modulator may have come from the stater issue. Now that I think about it I had to get a warranty replacement on my Mini-Beast II horn around the same time so there must be something there that I didn't put together before.

 

https://www.kisantech.com/index.php?cat_id=2


https://www.kisantech.com/popup/mult...roduct=P115W-S

Can also be found on E Bay for a bit less.


http://www.ebay.com/itm/H4-9003-HB2-...item23216d9cdc

 

should say on the bulb what wattage it is , you could go with HIDs cheaper than LEDs and if people don't see this , an't nothing going to help

 

I'll fart anywhere I please, as much as I want because it makes me feel better. I don't care that other people have to smell it...F-'em!