The high beams on my ke30 cut out the other night, low beams were fine. I checked the switch, and found that where the switch loom connects to the main loom, under the steering column, the high beam wire (red, Yellow trace) had got so hot, it had partly melted the plastic!

 

So I changed the switch, but the wire still gets bloody hot, even with the low beams on!

 

I can't seam to find and wire breaks, or shorts..

 

Its had a halogen conversion done, was 55/100 watt, but I thought the 100 watt might be drawing too much current, so I changed back to 55/60 watt, but no change...

 

Any ideas whats causing this?

if its getting hot it means it has high resistance or excessive current draw.

 

 

i rekcon you need a relay near the headlights to cope with the loads of the new lights. instead of 20-30 amps going through the light switch

 

correct me if I'm wrong?

Yes, make the relays do the work instead of burning out the switch-

 

Adapt this to the KE30

 

http://www.ke70.com/forum/index.php?showtopic=1856&hl=

Well if it's got hot and stopped working, it's already done the damage, you need to go around the circuit with a mulitmeter to find out where the open circuit is (that's what it would be now). And like people have said, put a relay down the fron of the car if you want to run higher wattage lights.....i'd even chop of the old lights plug and put new ones on cause the old plugs shouldn't be used with the new current flow.