Soooo I cut out the burnt spot on the yellow wire.
I discovered non insulated butt connectors! They allowed me to just strip off a small amount of insulation (1/4 inch) on each end, and used shrink wrap. Feels quite strong. Of course I experimented a few times on the bench, and luckily had the correct crimp-er specifically designed for the non insulated connectors. These connectors are very nice to use.
I can only think that the wire got caught by the chrome headlight ring, and with vibration, wore down the insulation to make a short.
I took apart the relay at one point and went through all the possible tests and put it back together.
At the suggestion of
the mechanic from hell!, which he is. I replaced the ceramic fuses. They had not failed but looked like 38 year old fuses.
All functions work again:
Park lights
Headlight goes off when starting.
Low Beam
High beam flasher w indicator
High beam w indicator.
I think this happened due to my improving the lights with the LED halogen replacement, which added to the stuff packed in the headlight shell. Maybe I should have removed the S faring during installation so I could better see what was going on inside the shell.
I was thinking of going back to the original Halogen bulb at one point. But I really enjoy the super bright lights and lower charger system load.
Thanx for your input!
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