Decided to buy some used 2006 Xenon Lights since mine were gutted by previous owner and were missing lots of parts.

Well, it seems that after years of heat? Most used lights have the wiring Insulation coming from the control unit to the igniter very brittle and even missing from varios length of wiring!
The Left light had lots of bare wire (photo uploaded) and the Right looked like a previous attempt to wrap in electrical tape each wire (not a very good job)

As you can see in pic the 3 wires going to the igniter are loosing their insulation! This cant be good!

The left light works fine, the right light has wiring issues and its intermittent. (move wire and light works sometimes)

I bought some liquid electrical tape to remedy this situación, but don't know if this will suffice.

Has anyone re-wired a version of these lights?
Does someone have a wiring diagram, so I can plan out the work needed and wiring colors needed (to keep wire color stock if possible)

 

Happened to a set I purchased off Ebay.

After awhile the coating wore out and they shorted out.

Currently in the process of rewiring the entire thing.

If yours isnt too bad right now you can get some liquid electrical tape and coat the wires so they dont touch.

 

Seems to be a known problem.

I found this website that has the igniter harness by itself, this would save a lot of time in rewiring!
This harness has the plug for the Control Unit and the Plug for the Igniter, exactly what Im looking for.

http://www.oemxenonshop.com/Mini-R53...placement.html

 

Seems then want $50 per harness side.

Need to analyze further.

 

Wish I knew about this before taking my lights apart!

 

Get some new H7 connectors in the appropriate socket (m/f) and just re-wire it. Should take 30min including soldering, shrink wrap, pinning the connector, etc., and now it'll be brand new and you have the opportunity to make it better than OEM.

 

Rewired the Igniter to Control unit (Ballast) harness, and everything is working perfectly.

Did not have to open Light (dissasemble / unglue) , was not that hard working new wires through and soldering a few patches.

The other light just received some liquid black tape for now.

 

I've seen the same sort of wire damage in halogen housings where 'hotter' bulbs had been used . . .

 

Yes absolutely, and this is why it's extremely unintelligent and uninformed to use anything beyond 55w Halogen in a factory housing with factory wiring (or in a factory housing utilizing plastic components even with upgraded wiring).