Lights Have Failed!

[MC680x0]

The problem is in the lighting circuit. The red/yellow is the main feed from the Headlight fuse to the lights on/off switch on the right hand bar. T...

I need say no more, its all here from the wonderful unfazed  mokin  but....

The red/yellow had burnt.. This feeds the main headlight bulb from both the pass and hi beam switches. to me this looks like a symptom of high current draw for a sustained time, through both switches. A stuck/faulty pass switch would allow two flows of current along the same line. The OEM connector he had on originally (?) had burnt and im not convinced it would allow arcing unless it was shot through inside.the terminals pins are enclosed within the block. .if we could look at the oldvterminal pins we could ascertain. I've never seen this arcing effect ,but entirely  possible? I think he had and had a problem upstream in the switch but he would need to get proper spec connectors as we have said then see if it burns out again....and then,well its either your arcing again with his new loom, or still that  faulty switch. Fizzypies: did the high beam dash light work and does it come on?
**EDIT***: Just thought of an arcing potential, rather than the wire end of the loom, the pin contact end is close enough for arcing to occur if there is some old strands of wire in there or some other conductive material. but the way that red/yellow wire has stripped down on both sides suggests to me a weak link at the loom not being able to carry the high current - and if this was happening before (with OEM loom) then I'd still plumb for a current draw issue from there being too much high current switches on (pass/hi/lo beam)


Also I wouldn't piss about with paying £10 for those little automotive packs... And you still need loom tape around it all to keep moisture out and prevent shorting... Etc

Get something like this instead http://m.ebay.co.uk/itm?itemId=231330354837 and give it a good clean with contact cleaner over the cables and in the connectors. You now have a rewiring kit should anything else go wrong with electrics, and it may well do on an old bike if it hadn't been maintained and cleaned well. You have already had one bad experience, tend to be like buses !