Cooked Headlamp Harness

[Dallara]

Re: Final Drive info

You're certainly right about all that Dallara. Perhaps we can get a Mod to move those posts over to the appropriate thread?

Dallara,

You're totally right. How do we go about getting a mod to sort the posts where they are easier to find?

Chris

You guys could just copy and paste your posts here over into those threads. Like I said, I don't see these as derailing this thread or anything like that, so no need to move 'em outta' here... I just think the info would be invaluable over in the various rear seal and final drive threads. In fact, if you guys do copy and paste the info over in those threads it would bring them to the top so more could see them - something having the mods move them over there won't do, IIRC.

Just a thought.

Dallara



~

 

[EricV]

As requested by Dallara, I copied and pasted reply #587 to the final drive seal frustration thread HERE

Link included here so Sail2xx knows where I put it and can add his reply more easily.

 

[Travex]

Pulled up behind a van at a light today and noticed my left headlamp is out. The bulbs are maybe a couple thousand miles old. The new replacement harness has only several hundred miles on it. I'll approach the dealer about this Monday and post results.

 

[tomatocity]

Spoke with the dealer service dept today and was told they (Yamaha) told them that only stock lamps should be used. I'm currently using Sylvania Siverstar Ultra's and don't believe I'll be spending $40.00-$50.00 to go back to the stock lamps. Granted, the Ultras don't have a great life-span, but they are my preference. More importantly, the Ultra is rated identically to the stock lamp and the difference in draw is non-existent. It's not as though I'm over taxing the scrawny harness/connectors. Frankly, it seems they're dodging the issue as 55 watts is 55 watts. In addition, as my new replacement harness is identical to the original (that failed using the stock lamps), it would be reasonable to suspect that this one will ultimately fail as well. Pushing this problem off to a later date will find a displeased customer if/when that potential failure recurs.
My initial sense is to simply make a beefier harness with ceramic ends, but as I'd like to see what direction this may go I'll be content to keep those parts and the tools for them in the toolkit.

Granted, every machine has it's idiosyncrasies, but between the hard start issue and the cooked headlamp harness my confidence on longer, more remote solo rides has been slightly eroded. I'm at the age and stage of life where getting stranded is troublesome rather than just another thing.

Before I purchased the PIAA H7 Extreme Bright White Bulb http://www.yamahamotorsports.com/sport/products/modelscitemdetail/5/651/2223/21116/2012/1/9002/0/1/detail.aspx I asked the dealership to check to see if it would not be covered under warranty. Their reply was Good To Go, covered under warranty.

 

[Travex]

A good point sir... Thank you. During one of my conversations there I had asked why Yamaha would endorse a non-stock (also 55 watt) lamp for the S10. That went unanswered, likely as it was not conducive to their dialog. Clearly, each lamp cannot be scrutinized past it's power requirement and basic specification compliance as that would simply invoke Magnuson-Moss. ::024::

Time will tell the outcome, but from what I've gleaned so far from this informed forum it appears the solution will come slow and hard. With respect to Sail2xxs's considerable experience with the issue there's certainly no shortage for anecdotal citing.
Then there's recourse, but I'm hopeful that talk of the FTC/Bureau of Consumer Protection and BBB never escape this sentence. I take quality and service seriously and believe ownership of problems is essential... Especially when it comes to swift vehicles traveling in the dark, let alone the daytime with severely diminished conspicuity. My wheel can squeak pretty loudly. Let's hope it gets something more than dielectric grease.

 

[tomatocity]

Don't take this negatively but Talk is Cheap. Sounds like you have talked enough with Yamaha. Find the people you need to send an email to and do it. The more the merrier on recipients. Don't forget to include your dealership.

On a Other side of the Coin note. I know of another rider in my area that used the same bulb as you did and ended up with with the Burn issue. He ended up building his own wiring harness. This kept me from using the Sylvania bulb. But I do use them in both my Honda Accord and Chevy S10.

 

[Travex]

No problem here... Of course you're right. There's one simple reason I haven't yet and it's that I hold my dealer (great reputation) in high regard and if they tell me they're on it, I'm going to assume they've got more swagger on the matter than I. That's not to say I won't assert the point directly with Yamaha or elsewhere should the problem not be addressed to my satisfaction very soon. As of two days ago I was informed by the service manager that the (recurring) problem is in Yamaha's loop and that they're (the dealer) maintaining the position that the harness appears to be problematic. I believe in the chain of command and if the dealer resource should exhaust their influence mine will be exacted unerringly.

Having just returned from a trip to north of Lake Huron I'm plenty disappointed by Yamaha in that seeing wildlife at the roadside has become a palpable challenge with "one eye". Naturally, that's just one disadvantage to being half-blind while riding. You'd think Yamaha would be on this like white on rice considering the potential liabilities.

Currently and for several years we've been using Silverstars in: Nissan Pathfinder, Hyundai Elantra, Subaru Forrester, Jeep Cherokee, Kawasaki KLR 650, KTM 690SM, and Yamaha WR250R. All without a hitch other than their slightly diminished lifespan.

Tomatocity... For all my reading on this issue I still haven't run into a manufacturing/fab source for a sturdily made harness. If you're aware of one I'd be thankful if you (or anyone) would point me in that direction as I don't wish to take on that task if it can be easily avoided. For a fab guy you'd think this would be a nice little item to offer.

I had a love affair with this bike and now it's cheating on me. It's time for therapy.

 

[jajpko]

You can make this yourself. Not really difficult, and if you need help, surely you must have a friend that knows about electricity.
Do a search for an inmate named Dallara. He posted some nice photos and some instructions. He never used his parts that I know of, so maybe he would sell them to you??

As far as only having one headlight, if the bulb is burned out, that is your problem. I always carry an extra bulb on the bike just for a situation like that.

 

[limey]

I just got an e-mail today from my dealer Yamaha Canada wants the bike for a few day to look into my cooked harness . Taking it in 28th of August. Let you guys know what happens.

 

[cb0802]

Mine went out today. Melted plastic all at the connection.

 

[Combo]

Some may have not seen this so I will post the link to I think page 19.

http://www.yamahasupertenere.com/index.php?topic=2707.msg140113#msg140113

I hope this helps some of the new guys to this one bike and not another sometimes issue.

 

[Travex]

You can make this yourself. Not really difficult, and if you need help, surely you must have a friend that knows about electricity.
Do a search for an inmate named Dallara. He posted some nice photos and some instructions. He never used his parts that I know of, so maybe he would sell them to you??

As far as only having one headlight, if the bulb is burned out, that is your problem. I always carry an extra bulb on the bike just for a situation like that.

True enough Japako. The electrical and bench experience isn't a problem... former Navy ET (electronics tech). Many pokers in the fire right now and sourcing the connectors will not be one of them. As mentioned I would purchase a completed assembly and at that I'd likely keep it on board as a backup. I believe the point here is to have the mfg address the problem accordingly. Pissing up the rope is the only thing that will accomplish that, and I'm doing that step by proper step. I'm willing to play that long game and take one for the team. In the meanwhile I carry my spare lamp(s) as well as parts and tools for an impromptu fix. Thanks for the tip.

With respect to my latest failure, I'm taking the bike to the dealer tomorrow so they can check it out. We agreed that I wouldn't even remove the dome unless I had to so they could view a pristine, untouched condition. On that note, it's encouraging to see Limey's post indicating Yamaha Canada's interest in assessing the problem. I look forward to hearing of that outcome.

I enjoyed Dallara's post(s) and am thankful to him for this thread.

 

[sail2xxs]

Got my harness swapped out today - had both headlights when I pulled into the dealer.... started it up to ride into the shop bay, and right headlight went out. Perfect timing.

I was told that Yamaha is actively working on a solution, and that it will most likely be similar to the fix they used for the FJRs, which had the same issue.

The replacement harness was not modified with the extra ground wire - curious to see how long it holds up!

Chris

 

[vnp514]

Easy there boys. ::005:: The wiring is not ideal. And yes, it can be improved upon. But it's also not something every bike is having issues with. It's not a "flaw", it's a design parameter we don't all feel was the best choice and some are having real issues with. This thread is about those issues and correcting/repairing/preventing them and has a lot of good first hand info and excellent posts with options on altering the wiring to either correct an existing problem or prevent one for those wishing to take preventative steps.

I'm pretty sure most Tenere owners will not suffer the burnt right side headlight plug syndrome. This doesn't make the issue any less real, it's just that it's not something every owner will need to deal with or worry about.

Add another cooked HL harness. 2012 ST with a little over 13,000 miles. Stock bulbs used. Left side is cooked:





Right side looks okay:



When do we consider "most owners" are or will have this problem? ::010::

Pete

 

[snakebitten]

Hopefully we don't all experience it. I, for one, soon after this thread got going, did some preventive treatment. As well as an occasional inspection.

So far so good.

Did burn a bulb out finally at around 30,000 miles. Surprised they last that long due too all the off road bouncing and bashing. Gotta be a real bulb jiggler.

 

[creggur]

Hopefully we don't all experience it. I, for one, soon after this thread got going, did some preventive treatment. As well as an occasional inspection.

So far so good.

Could you relay or link to your preventative treatment?

My first harness made it just over 10,000 miles before problems started.

 

[snakebitten]

It's buried in this thread. But it amounts to simply filing all the plastic off the connector housing that gets in the way of the actual metal connector.

If you look closely, it looks like one side of the mould they used was not made correctly and so the plastic housing has excess material that can compete with good solid metal to metal contact between the harness side connector and the bulb itself.

Also, once you have made sure the plastic has been filed back, verify the actual female connector isn't spread\sprung. It needs to fit the bulb tightly.

And finally, clean any oxidation from all metal parts and apply some dielectric grease.

Basically you are addressing the theory that with a poor connection, there is additional resistance. That increases the thermal conditions. If left untreated, it finally gets hot enough to melt the plastic connector and insulation on the wires.

Others have done away with the OEM connectors altogether. They purchase ceramic connectors. I suspect that will be my solution if my preventive attempt ever turns into folly.

That, and I will sneak over to Corpus Christi and snag that unused harness that another owner built but never used.

 

[vnp514]

Okay,

My game plan is to go with the ceramic connectors. These are the ones I want-right?:

http://www.ebay.com/itm/HARNESS-H7-X-2-WIRES-CERAMIC-PLUG-CONNECTOR-HEAVY-DUTY-AFTERMARKET-LOW-HIGH-FOG-/160654238893?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item2567bd24ad

I'll splice them into my stock wiring but being electrically challenged, might I have a mini class on how to do this? (I probably don't just twist the wires together and tape them up with electrical tape.) Tell me how to do it right the first time.

Thanks

Pete

 

[EricV]

Okay,

My game plan is to go with the ceramic connectors. These are the ones I want-right?:

http://www.ebay.com/itm/HARNESS-H7-X-2-WIRES-CERAMIC-PLUG-CONNECTOR-HEAVY-DUTY-AFTERMARKET-LOW-HIGH-FOG-/160654238893?pt=Motors_Car_Truck_Parts_Accessories&vxp=mtr&hash=item2567bd24ad

I'll splice them into my stock wiring but being electrically challenged, might I have a mini class on how to do this? (I probably don't just twist the wires together and tape them up with electrical tape.) Tell me how to do it right the first time.

Thanks

Pete

No, those would only transfer the bad connection to a point farther down the line. This is what you want, imho, and what I used. Cut off the oem connector and solder in the new one.
http://www.ebay.com/itm/2-Pcs-Right-Angle-H7-Ceramic-Headlight-Bulb-Connector-Plug-Socket-for-Car-Truck-/380569012856?pt=Motors_Car_Truck_Parts_Accessories&hash=item589bae4a78&vxp=mtr

Or Click HERE (same link)

 

[vnp514]

Thanks Eric!!

Pete