Cooked Headlamp Harness

[Checkswrecks]

Very strange if wire insulation is melting midway in the harness. The only way in the world the wire could possibly heat is from excess current, and I doubt 5A is overdraw for the wiring, or bad connections at the plugs, and if this is the case the wire will burn right where the bad connection is. The remainder of the wire will actually be carrying less current than preburn because of the voltage drop at the bad connection. Of course heat can wick down the wire for some distance and still melt insulation a ways away from the plug. This would be the only real explanation, still bad plug causing the problem, not the wiring unless they are using 24awg wire. They do use 18awg or so I would assume?

Not so strange, as the damaged area of the wire is in the sleeve, while the connector and last half inch of wire are exposed to whatever air movement exists.


I've been part of a group doing IR heat mapping on wire bundles in older airplanes and it doesn't take much to change the temperature in just an inch of distance.

 

[roy]

Thread resurection. Well it looks like the headlight gremlin has affected my bike. Got ready to leave for work this morning and noticed my left headlight was out. I instantly knew what was the cause. I rolled her back into the garage and pulled the headlight cover. It appeared okay so I unplugged the plug and pulled the bulb, bulb was not blown. I focused my attention back to the plug, sure enough a slight discoloration on the gray wire right at the plug. Not bad but the begining of the end for it I'm sure. I put the bulb back in and reattached the plug onto the bulb and the light is working. Rode to work rechecked it and it seems they get warm in there on both sides. I have been monitoring my bulbs for months now since this first surfaced. I just checked them this past sunday and didn't notice anything unusual. The plug came off real easy the first time so I am thinking it's working loose some how with vibration then causing the short in the connection. Just my shade tree observation. I reattached the plug and then tried to remove it and it was much harder when properly seated verses the first time I removed it.

Anyway headed to the dealer shortly. I have a trip in 4 weeks so this needs to get repaired quick as I don't have tome to waste or I'll inplug both headlights and run the Denali's full blast :'(

 

[hojo in sc]

Thread resurection. Well it looks like the headlight gremlin has affected my bike.

Anyway headed to the dealer shortly. I have a trip in 4 weeks so this needs to get repaired quick as I don't have tome to waste or I'll inplug both headlights and run the Denali's full blast :'(

How many miles do you have?

 

[roy]

How many miles do you hav ::015::e?

Just rolled 8200 this morning. Mine was one of the first to hit the states last July.

 

[roy]

Well I took it in to the dealer. They kept the bike, took me back to work so now I'm stranded here for the day. They were calling yamaha when I left. Not what I expected. I thought they would look at it, verify or guess the problem then let me leave as a part was ordered. Wasn't prepared for this.

 

[pqsqac]

Keep us posted please. I just had both lamps go on me the other day but that was a bulb problem with PIAA bulbs not cutting the mustard. Still I keep an eye on my harness as well. Running stock bulbs again and wow they are brite when new.

Well I took it in to the dealer. They kept the bike, took me back to work so now I'm stranded here for the day. They were calling yamaha when I left. Not what I expected. I thought they would look at it, verify or guess the problem then let me leave as a part was ordered. Wasn't prepared for this.

 

[roy]

Keep us posted please. I just had both lamps go on me the other day but that was a bulb problem with PIAA bulbs not cutting the mustard. Still I keep an eye on my harness as well. Running stock bulbs again and wow they are brite when new.

I certainly will Vince. I was sort of caught off guard by them wanting me to leave it this morning but I plan on hitting them up for a loaner to ride home this afternoon. There is a black shiny new S10 sitting on the showroom floor that is their demo and it just maybe be the ticket home this afternoon. >

The mechanic who is a good friend, we go back about 20 some odd years, told me to call Yamaha customer service and voice my opinion with them. I was hesitant to do that since I don't want to ruffle any dealership feathers but he straight up told me they need to hear from me about it. I've tried calling twice this monring but gave up with the over 10 minute waits on hold. Will try again later today.

 

[Dallara]

~


E-mail 'em... Repeatedly and often. Eventually they will respond.

IMHO, it's a lot less frustrating that calling them. ::013::

Dallara




~

 

[roy]

Yamaha customer serivce is a no go. Complete jerk! Nice lady at first was understanding and helpful then I get the product support guy, forget it he knew everything and I was the idiot. I was accused of using higher wattege bulbs, NO I didn't, Sir the internet is not where you go for problem solving, excuse me all these people with problems didn't just wake up and dream their harness melted. He said my dealer had contacted regional rep and that pictures were requested then they would procedd from there. My harness is not melted enough for it to really show in a picture but with the naked eye you can tell it's beginning to melt. The only reason it has not gone full on Fukishima yet is because I was anal enough to keep checking the damn lights and caught it before the short melted it all down into a puddle. He told me this was the first he had ever heard of a Super Tenere harness problem, probably becasue it's his first day on the job. I got news for them I was nice this call, I won't be so nice the next call. This is not my first rodeo with motorcycle manufacturers. I've owned 30+ Suzuki's over the years so I have practice with this sort of thing. Yamaha should be the one worrying not me because when I come at you with both barrels you will know you've been hit.

Not impressed at this point but I really didn't expect anything more to be honest. Today the customer is the idiot in their eyes. They hire these know it all types who don't know jack about the product they defend so bravely. They do what they are told to do.

 

[roy]

Oh and before I get too excited this will be my first and LAST Yamaha!! to think I waited a year for this thing and I have one problem and get treated like a complete second class citizen by some pencil pushing ass hole. They don't deserve my money and I plan on telling who ever will listen that to.

 

[sail2xxs]

Can the dealer pull the harness off the other S10 on the floor? My next to last visit to Romney Cycles, it turned out that I needed rear brake pads, which were not in stock. They pulled the fresh set off a floor bike, and I was good to go.

Pics of my headlamp harness issue are attached if they help in any way.

Chris

 

[sail2xxs]

Oh and before I get too excited this will be my first and LAST Yamaha!! to think I waited a year for this thing and I have one problem and get treated like a complete second class citizen by some pencil pushing ass hole. They don't deserve my money and I plan on telling who ever will listen that to.

It's your choice, but most 800 number customer service folks are not really helpful. A good dealer, and a good regional rep make a tremendous difference. I have a Yamaha shop about 5 miles from my house, but choose to ride 180 miles one way to get my bike serviced at a shop I trust, that has an excellent service department, very helpful, interested, regional rep, and a great sales/parts department.

Chris

 

[roy]

Can the dealer pull the harness off the other S10 on the floor? My next to last visit to Romney Cycles, it turned out that I needed rear brake pads, which were not in stock. They pulled the fresh set off a floor bike, and I was good to go.

Pics of my headlamp harness issue are attached if they help in any way.

Chris

Mine is no where near that bad but it will eventually get to that point it's already started. I'm not the waiting type I want it fixed now not when I'm 2k miles from home in the dark with a flashlight taped to the front. Thanks for the pics I'm tempted to email them to Mr. Product support jerko since this is not happening and all in my mind.

 

[roy]

It's your choice, but most 800 number customer service folks are not really helpful. A good dealer, and a good regional rep make a tremendous difference. I have a Yamaha shop about 5 miles from my house, but choose to ride 180 miles one way to get my bike serviced at a shop I trust, that has an excellent service department, very helpful, interested, regional rep, and a great sales/parts department.

Chris

That will be discussed if this drags on beyond next week. Dealer has been helpful and is the only reason I bought the bike there. The dealer is the only reason I called yamaha they encouraged me to. Wish I had not now since I'm fuming mad about the whole ordeal. Mr. Product specialist just lost them a customer. My next communication with them will confirm this also. I don't take crap from companies. Instead I move on and spend my money elsewhere where it is appreciated.

 

[Dallara]

Oh and before I get too excited this will be my first and LAST Yamaha!! to think I waited a year for this thing and I have one problem and get treated like a complete second class citizen by some pencil pushing ass hole. They don't deserve my money and I plan on telling who ever will listen that to.

That's certainly up to you...

But sometimes it helps to remember that nothing built by man is flawless. I've been riding well over 40 years, was a Honda dealer for over 11 years, was a line motorcycle mechanic for years before that, and have owned goodness only knows how many motorcycles (own 14 right now! ??? )... And just about any brand you can imagine - Aprilia, ATK, BMW, Bultaco, Can-Am, CZ, Ducati, Harley-Davidson, Honda, Husqvarna, Kawasaki, KTM, Norton, Penton, Suzuki, Triumph, Yamaha, etc. - and have no brand has been free of problems (one of my Suzuki's was one of the worst!). But just as anything built by man can have problems, any of those things can be fixed.

I believe I was the first on this forum to report the headlamp harness problem. Yes, I had to dance a bit with Yamaha to get a new harness from Yamaha, but my dealer was stellar during the entire episode. Yes, I went ahead and prepared for the worst even after I got the new harness and have one in progress that will never fail (if I ever stop riding the bike long enough to finish it! ). Yes, I was ticked off at Yamaha when it happened, and at the morons I spoke to on the phone at Yamaha... That's why I mentioned e-mailing anybody and everybody, including higher-ups, at Yamaha in Cypress.

But all that said, I was one of the first to order a Super Tenere in the USA. It arrived at the dealer's July 28, 2011 and I took delivery on August 3, 2011. I now have over 12,800 miles on it, and other than the headlamp harness the bike has been *FLAWLESS*! Not one hiccup, nor one other problem. Just typical Yamaha reliability and dependability. As an aside I should again note that out of all the Japanese brands I have owned Suzuki was the worst, and oddly enough Yamaha's have been the best (and remember, I was a dyed-in-the-wool Honda dealer, as well as fanatic!).

Again, it's up to you, but you might want to give the bike another chance.

Just my two centavos... YMMV.

Dallara



~

 

[roy]

I hear what you are saying and I too was one of the first in line. Waited the entire time patiently and for the most part am happy with it BUT I totally got the jacko feeling this morning from them. I still can't believe I took it so softly but as time has wore on I feel they are due for the real me to step forward. I am bumming a ride to the dealer here shortly during my lunch hour. Mr. Personality said they are waiting on pictures and I want to expedite this to the dealer. I don't like to get the we've nver heard of this and for one I'm not one to dream up stuff and I don't go looking for problems that do not exist. I ride and for the most part really just do not sit around hoping I will have a problem.

I do not think talking down to me was the correct approach for this guy and I hope we have another talk. I will out right buy another harness and roll this thing to the dealers used bike for sale lot in a heart beat. I don't play these games. There is simply to much competition out there and people who really want your business not folks who have it and abuse it. And I don't expect perfection, hell I bought 30+ Suzuki's so I'm a gluten for punishment but I can tell you without a doubt I never had a headlight melt on a Suzuki.

 

[Dallara]

...And I don't expect perfection, hell I bought 30+ Suzuki's so I'm a gluten for punishment but I can tell you without a doubt I never had a headlight melt on a Suzuki.

Your 'Zooks may not have melted a headlamp harness, but trust me, you don't want to get me started about the multiple problems I had with Suzuki's!!! ::015::

Nor is this the time or place!

Of course, that doesn't negate the fact I still do believe that Suzuki makes their bearings out of high-grade mahogany, and their fasteners, most of their engine materials, and certainly their gearboxes and clutches out of the finest butter available!

Dallara



~

 

[sail2xxs]

Mine is no where near that bad but it will eventually get to that point it's already started. I'm not the waiting type I want it fixed now not when I'm 2k miles from home in the dark with a flashlight taped to the front. Thanks for the pics I'm tempted to email them to Mr. Product support jerko since this is not happening and all in my mind.

Send product guy the pics. This is not an isolated event, but most product folks do not really know their product. I had a hell of a time with Toyota trying to get informaiton about the FJ Cruiser. In the end, it was the owner's forum and a good dealer (again, not the dealer close by, but one 50+ miles away) that got the answers I needed to make what I thought was an informed decision.

Chris

 

[Checkswrecks]

Again, when you have a problem that may affect safety, log it at www.SAFERCAR.GOV or the direct address is https://www-odi.nhtsa.dot.gov/ivoq/ To me, losing the headlights at night qualifies. When I get my harness replaced soon I'll log it.

We learned with the FJRs that this is the one site that Yamaha truly pays attention to. The reason is that this is a government site that leads to recalls. Logging is quick and easy.

For all the bitching about spokes and lights, I just checked and there is only ONE complaint shown for ALL of the Super Teneres in the US and it is about a wheel, presumably for the loose spokes.

We also learned with the FJRs that Yamaha seems to not give much feedback to their customer service people. They get what they need, but by the time they learned of any recall, we already knew of it on the FJR forum and had more details than they did. Yamaha may've taken their time on a couple but they did work the issues in the back room while not letting on with us. The company replaces valve shims, top box brackets, etc that were WAAYYY out of warranty and they did so for a lot of people.

And finally, not as a criticism, but for the next person or time. When the dealer says you have to leave your bike, NO YOU DON'T have to. It is still your property and your decision. If it 'd give them a call and simply remind them of the fact and tell them I'm on the way to collect what belongs to me.

Again, PLEASE file a complaint with www.SAFERCAR.GOV

 

[roy]

Your 'Zooks may not have melted a headlamp harness, but trust me, you don't want to get me started about the multiple problems I had with Suzuki's!!! ::015::

Nor is this the time or place!

Of course, that doesn't negate the fact I still do believe that Suzuki makes their bearings out of high-grade mahogany, and their fasteners, most of their engine materials, and certainly their gearboxes and clutches out of the finest butter available!

Dallara



~

Hmm never had any problems like you mention and I have hammered their GSXR's for years on the racetrack but they would occasionally dropa valve as the miles accumilated but so does the R6. Nothings perfect as you earlier mentioned but I do think some in the corporate world should listen to the customer base we are not all idiots.