ok were talking about headers here right?
like the reset switch, and hdd / power LED?
These would be OK to short / swap while on:
1. The reset button... it works on a short principle anyhow, so if u short it while pc is on, at worst you'll just reset it.
2. The power button.. this works on a momentary switch. Again, its a switch principle.... if the headers detect a short, it thinks the button was pressed, and like you pressing the power button will shut the PC off. I short this all the time when the boards i work with do not have a switch directly on them, and i am too lazy to find my momentary switches.
3. LED - Why can you not plug these in when the PC is on? I am lost, who says you cant?
It is a 3V LED! It draws very little current. The LED will not fry the header, you may however fry the LED if your unlucky. But this is if your unlucky. And some case manufactors are CHEAP as hell and cant use a dual polarity LED, so sometimes you plug them in wrong, and well, it wont light up because the polarity are reversed, and you have to flip them.
So yes, the front headers are OK to swap out as long as you know what headers the are.