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Thread: Headlight wiring meltdown!

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  1. #1
    Rally Rat warthog's Avatar
    Join Date
    Aug 2005
    Colorado Springs, CO

    Angry Headlight wiring meltdown!

    This is what happens when you replace a 55w bulb with a 100w bulb on an 2002 1150 GSA. Your headlight wiring melts down because the circuit is not protected. Anyway I traced it back to the main harness and looks like it continued to melt inside the main harness.

    I am assuming I have to replace the main harness so I picked up a wiring harness for a 2001 GS of eBay for $115 and the part numbers match with the 2002 GSA. FYI dealer cost is $1500+.

    Looking for any advice or tips before I jump into this project.

    P.S. no I did not mean to put a 100w bulb in I should have grabbed my reading glasses before I installed the bulb. Getting old sucks

  2. #2
    Registered User
    Join Date
    Sep 2006
    Diamondhead, MS
    Wow !
    Its too bad those bulbs don't have different pin arrangements on them. Good luck wit,h the project.
    '03 R1150R, '03 F650GS, '97DR200SE,'78 Honda CT-90, '77Honda CT-90

  3. #3
    Registered User roger 04 rt's Avatar
    Join Date
    Oct 2011
    I don't understand why only some of the circuits connected to the Load Relief relay are fused.

    The heated grips and horn circuits each have their own fuses, while the headlights (low and high beam) and corner lights (flasher) aren't. It doesn't seem to make sense.

    Then in 2004 BMW added a fuse to the high beam lamp but not the low beam.

  4. #4
    Registered User rxcrider's Avatar
    Join Date
    Aug 2010
    North Ridgeville OH
    How long did it take for this to happen? I've had a 100 W high H4 in my bike for most of this year and haven't had any issues. I only run the high beam at speed out of fear of overheating the lamp housing, but I haven't noticed any wiring issues. We are talking about a less than 10 A load @ 12 V. That isn't all that much.

  5. #5
    Curmudgeon At Large Bobmws's Avatar
    Join Date
    Mar 2003
    Astatula, FL
    Add relays to your headlights and a beefier ground wire. This is not a new issue on BMWs.
    Bob Weis
    '04 K12RS - Hannigan Hack

  6. #6
    Unfunded content provider tommcgee's Avatar
    Join Date
    Dec 2006
    Braintree, MA
    Go to the Eastern Beaver website and buy a relay harness for your headlight circuits. Tons of info there.
    Salty Fog Rally 2007, 2009, 2011, 2012, AND LOOKING FORWARD TO 2014!

    -Tom (KA1TOX)

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