Headlight ground wire
 

Started the bike today and the headlight wouldn't work. Pulled it off and the ground connecting directly to the light socket was corroded and melted. It is one of the 15 watt thailand replacement headlights. The wires they used are a lot thinner than the originals. Could that cause this? Thoughts?

It sounds like you might of connected power to the ground. Test the light using a latern battery. Ground the light to the negitive contact directly against the light body, then touch the positive wire(s) one at a time to illuminate the bulb.

If the light works with the ground directly against the light body then fix the melted wire and re install the light connecting the correct wire to ground.

Or..if the wire that melted is indeed the ground, then replace the wire with the next larger wire and re check the light using the latern battery.

Rewired it with thicker wire. Seems to be great. Thanks