Wistrick said:
please tell me that the dealer did not smear di electric grease on the problem.....Stop Stop Stop using di electric grease on connectors its an insulator......
http://ftp.pwp.att.net/w/a/wayneorwig/Dielectric_grease.htm
and yes I know you been using it on your motorcycles since the 60's still doesn't make it the right...
Dan
Yes, Dan...
Dielectric grease is an insulator, but that still doesn't alter the fact that literally every single motor vehicle manufacturer in the world, plus every race preparation shop I've encountered in my travels, recommending the application of dielectric grease compounds in nearly all electrical connections throughout their vehicles. You need only pull apart a few connector plugs on just about any car produced in the past few years to see it smeared in the connection...
Why?
Because it helps preclude corrosion and assist in keeping any moisture out of the connection and electrical system. Due to the design of various types of pin, spade, clip, etc. type connections the application of such dielectric grease does *NOT* keep any connections from being made, nor "insulate" any two contacts from making electrical connection with each other. Swabbing the grease on the plugs coats the metal surfaces, but as the connector is pushed together the actual tension of the two mating surfaces of the connection *pushes* or *squeegees* the grease out of the way where the actual electrical contact is being made and the proper connection is made. This leaves the remainder of the grease to completely coat and encircle the connection, hopefully *sealing* it from any moisture or other agents that might allow corrosion to start. Corrosion, and the additional resistance it produces - along with the fact that sufficient corrosion can actually make the contact area in connections like spades *lift* apart, breaking the connection.
In other words, in the world of vehicle electrical connections dielectric grease is by far the lesser of two evils. Just a quick Google search will show you that not only do the major motor vehicle manufacturers highly recommend the use of dielectric grease on connections, but many (like Ford, Honda, GM, Chrysler, etc., etc., etc.) actually sell several different types under their own brand label of chemicals...
switchback said:
I have noticed that the connectors for the headlights do not fit tightly. A loose connection will cause corrosion, increase resistance and fry the wiring. The ceramic socket has little to do with the fix, it is the tighter fitting connectors within the new connector that are the cure. During my HID install I noticed the spades in the sockets were not snug at all and would pull out with the lightest pressure. A quick crimp of the stock female connectors and a dab of solder on the wire for good measure would likely make this a non-issue.
Good observations...
But just as a quick aside and FYI, all of those same observations and suggestions as a solution have been mentioned here in the thread before, and tried by many. Some with success, while others have still had the problem repeat itself, like Chris/Sail2xxs. Even a quick perusal of the thread will show your suggestions, along with others, have put forth as "cures", yet the problem persists.
Unfortunately, it appears that this is, indeed, a design problem where the entire headlamp sub-harness is operating right on the edge of what's necessary, and as such the problem continues. It seems that until Yamaha decides to completely re-think and re-design this part of the electrical system of the Super Tenere it's going to be up to the individual owners out here in the field to come up with more robust and reliable re-fit solutions, at least for the time being.
Dallara
