I've seen it before. Those connectors are not up to handling dual headlight voltage long term. I have long recommended installing headlight relays to take the load off the stock contacts and connectors.

http://www.stromtrooper.com/general...neral-v-strom-discussion/55005-low-headlight-out-found-issue-best-solution.html

 

His was the black/white ground wire from what I have seen on the schematic.
Lost all dash and headlights.
You think just the Eastern Beaver bypass kit will cure it from happening again?
Mike

 

The ground wire and a headlight hot wire carry about the same current, at least close enough for the poorer connection of the two to burn out. Headlight relays move that load to the relays. The connection still needs to be fixed but adding relays is very likely to prevent it from happening again.

 

Sorry to wake an old thread - trying to find info that might already be out there. I'm having intermittent headlight failures (I don't think it's the starter switch - taken that apart twice now). Perhaps it's this plug you have a photo of here. Imagine I'm a complete mechanical idiot. Where is this plug that you have a photo of? Is it under the seat? Thanks. Peter.

 

Left side front fairing needs to be removed to access it.
Mike