Headlight wire harness recall how involved is it?

Don in Lodi

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LOL, my shop needs the whole bike. My relationships skills must suck, and they're 55 miles away, on the other side of a major metropolitan area.
 

viewdvb

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If Yamaha is prepared to foot the bill, why not let the dealer do it? It doesn't involve any parts that they could screw up badly. I wouldn't let the dealer lay a hand on my brakes or other vitals (too many bad experiences) but I let them do this job and everybody was satisfied - I got the new harness fitted, they and Yamaha got to tick the right boxes. If they are bitching about the extra time to remove crashbars (that was necessary with mine cos the side panels wouldn't come off with them fitted), remove them yourself before you take the bike in.
 

OldRider

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Don in Lodi said:
LOL, my shop needs the whole bike. My relationships skills must suck, and they're 55 miles away, on the other side of a major metropolitan area.
Don, you should be able to get the wire harness for around $30-$35 and put it in youself faster than you can ride to the dealer.
 

Don in Lodi

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True. Now that I actually have some charcoal showing, I need to do something about it.
 

Cycledude

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Ok what was the reason for the headlight harness recal ?

On my bike the left headlight goes out about once a week, first time it happened I just removed the cover and touched the plug and the light came on and stayed on. About a week later it went out again so I put some dielectric grease on the prongs, after a week it went out again so I put in 2 brandnew bulbs and a week later the left bulb is out again. Is there a way to tell if the recall has been done to this bike ?
 

EricV

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Cycledude said:
Ok what was the reason for the headlight harness recal ?

On my bike the left headlight goes out about once a week, first time it happened I just removed the cover and touched the plug and the light came on and stayed on. About a week later it went out again so I put some dielectric grease on the prongs, after a week it went out again so I put in 2 brandnew bulbs and a week later the left bulb is out again. Is there a way to tell if the recall has been done to this bike ?
Fill out your profile, it helps with questions like this to know what year bike you have.

The '12 model year bikes had a smaller gauge wiring harness for the headlights. It spec'ed out as just barely adequate for the current, but headlight plugs were melting and Yamaha eventually did the recall. I don't recall exactly what year range applied to the recall, but it has long been done in most cases. If you don't have a '12 model year Super Tenere, odds are it's not part of the recall. If you do have a '12 bike, your dealer should be able to confirm if the recall was done or not. It simply involved a new harness for the headlights that had thicker gauge wire and better plugs. Lots of people, including myself, replaced the oem headlight bulb plugs with ceramic H7 plugs sourced off ebay, which solved the problem of melting the plugs and having a headlight go out. Sometimes the bulb would be taken out too, other times the bulb was fine.

When the recall was done on my bike, I did save my ceramic plugs and did notice that the old wiring was heat affected, turning the black wire more gray, for example, but I did not see any other indications of melting.

Hope that helps. It's also possible that you simply got some bad bulbs. It happens. Look for indications that your bulb plugs are melting, and see if the connectors inside the plug are tightly gripping the bulb terminals. Some squeezed them with pliers to get a better fit to the bulb prong terminals, which seemed to improve things at the time, until the plug melted.
 

Cycledude

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Well my profile is filled out, but I didn't see anywhere to put the year bike I happen to own, my Tenere is a 2013 without electronic suspension, I bought it used from the same dealer that sold it when it was brandnew, I think it was some sort of consignment deal . When I bought it there was a headlight out and they agreed to fix it before I picked it up which they did, there ain't nothing wrong with the bulbs, I even changed bulbs to make sure that wasn't somehow the problem, so far it's only been the left bulb that quits working. Now that I'm aware of the harness issue I will probably check with a different dealer closer to home about getting it replaced.

EricV said:
Fill out your profile, it helps with questions like this to know what year bike you have.

The '12 model year bikes had a smaller gauge wiring harness for the headlights. It spec'ed out as just barely adequate for the current, but headlight plugs were melting and Yamaha eventually did the recall. I don't recall exactly what year range applied to the recall, but it has long been done in most cases. If you don't have a '12 model year Super Tenere, odds are it's not part of the recall. If you do have a '12 bike, your dealer should be able to confirm if the recall was done or not. It simply involved a new harness for the headlights that had thicker gauge wire and better plugs. Lots of people, including myself, replaced the oem headlight bulb plugs with ceramic H7 plugs sourced off ebay, which solved the problem of melting the plugs and having a headlight go out. Sometimes the bulb would be taken out too, other times the bulb was fine.

When the recall was done on my bike, I did save my ceramic plugs and did notice that the old wiring was heat affected, turning the black wire more gray, for example, but I did not see any other indications of melting.

Hope that helps. It's also possible that you simply got some bad bulbs. It happens. Look for indications that your bulb plugs are melting, and see if the connectors inside the plug are tightly gripping the bulb terminals. Some squeezed them with pliers to get a better fit to the bulb prong terminals, which seemed to improve things at the time, until the plug melted.
 

EricV

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Cycledude said:
Well my profile is filled out, but I didn't see anywhere to put the year bike I happen to own, my Tenere is a 2013 without electronic suspension, I bought it used from the same dealer that sold it when it was brandnew, I think it was some sort of consignment deal . When I bought it there was a headlight out and they agreed to fix it before I picked it up which they did, there ain't nothing wrong with the bulbs, I even changed bulbs to make sure that wasn't somehow the problem, so far it's only been the left bulb that quits working. Now that I'm aware of the harness issue I will probably check with a different dealer closer to home about getting it replaced.
Thanks for filling out your profile. You can put your bike year in the personal text, which shows up under your profile info, or in your signature area, if you choose to.

As someone said on the other thread, '12 and '13 model year bikes were affected by the headlight harness recall. It should have been done before you bought it, but I suppose it's all in the timing. Try going here and putting in your VIN to see what recalls apply for your bike: https://vinrcl.safercar.gov/vin/
 

Checkswrecks

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Eric is steering you right and your local Yamaha dealer can run your VIN easily to see if the recall has been done.
[/size]
[/size]That said, the recall was about burning up the wiring harness, not about blowing bulbs. You might stick a multimeter on the bike, rev it and see how high the voltage gets.
 

EricV

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If your bike is part of the recall, and it was already done, PM me and I'll send you the ceramic plugs, if you would like to swap your oem plugs out and see if that improves things. It will require some wire cutting and soldering or splicing with crimp connectors.

CW has a good point though, if you're blowing bulbs, there are some other things that could potentially be issues. Just not as well known as the headlight harness recall issue.
 

Cycledude

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Thanks for all the replies, I think there was a slight misunderstanding my Tenere has never burned ou a bulb but with the trouble I was having I decided to just replace them to make sure the bulbs didn't have something to do with it.


Took the vin number to my local dealer yesterday, yes there was supposed to be a headlight wiring recal on my 2013 Tenere but the dealer I bought it from never did the recall , thier service department must not have been paying much attention because when I looked at it they agreed to fix the left headlight that wasn't working, yes it was working when I picked it up but it's been going out about once a week ever since. they also claimed they checked the air in the tires but the day after I got home the rear tire was at 25 psi , so I pumped it up to 38 and it stayed there until 4,000 miles later when I replaced the tires. They claimed they changed the oil and final drive fluid so now I'm wondering what they ever actually did and didn't do besides wash it.
My local dealer ordered the recall kit yesterday, supposed to arrive Thursday so it should be fixed soon, over the years I have done a lot of business with my local dealer and they always treat me very well.



EricV said:
If your bike is part of the recall, and it was already done, PM me and I'll send you the ceramic plugs, if you would like to swap your oem plugs out and see if that improves things. It will require some wire cutting and soldering or splicing with crimp connectors.

CW has a good point though, if you're blowing bulbs, there are some other things that could potentially be issues. Just not as well known as the headlight harness recall issue.
 

Checkswrecks

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So the dealer you bought from sold you the bike and never spent the labor on the "We Owe" stuff?
Shocking
::)
 

Dogdaze

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Checkswrecks said:
So the dealer you bought from sold you the bike and never spent the labor on the "We Owe" stuff?
Shocking
::)
Shocking indeed, never thought I'd see that day when stealers; I meant dealers skimped on work that they get paid to do. ::017::
 

EricV

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Glad you got it sorted.
 

tpak

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EricV said:
Thanks for filling out your profile. You can put your bike year in the personal text, which shows up under your profile info, or in your signature area, if you choose to.

As someone said on the other thread, '12 and '13 model year bikes were affected by the headlight harness recall. It should have been done before you bought it, but I suppose it's all in the timing. Try going here and putting in your VIN to see what recalls apply for your bike: https://vinrcl.safercar.gov/vin/
All '012s should have been done ... I was lazy and then had a season off after a car accident and just now actually just walked back in from picking mine up from the dealer. I was absolutely having headlight bulb issues just as the recall describes:

Yamaha Motor Corporation USA (Yamaha) is recalling certain model year 2009-2013 YZFR1 motorcycles manufactured October 2008 through August 2013 and 2012-2013 XTZ12 motorcycles manufactured October 2011 through August 2013. In the affected motorcycles, use of the headlight may generate enough heat to cause the bulb connections to expand, resulting in arcing in the headlight bulb socket which could cause the socket to overheat, melt and cause the headlight to malfunction.

Also. I had the O-Ring recall performed back in '12 right after I bought the bike used - the Yamaha system had no record of that so the dealer did it again just to be sure. Hopefully this solves my bulb burn out issues once and for all. Should have done it a long time ago but that is my fault not the dealers.
 

Cycledude

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What o ring recall ?

tpak said:
All '012s should have been done ... I was lazy and then had a season off after a car accident and just now actually just walked back in from picking mine up from the dealer. I was absolutely having headlight bulb issues just as the recall describes:

Yamaha Motor Corporation USA (Yamaha) is recalling certain model year 2009-2013 YZFR1 motorcycles manufactured October 2008 through August 2013 and 2012-2013 XTZ12 motorcycles manufactured October 2011 through August 2013. In the affected motorcycles, use of the headlight may generate enough heat to cause the bulb connections to expand, resulting in arcing in the headlight bulb socket which could cause the socket to overheat, melt and cause the headlight to malfunction.

Also. I had the O-Ring recall performed back in '12 right after I bought the bike used - the Yamaha system had no record of that so the dealer did it again just to be sure. Hopefully this solves my bulb burn out issues once and for all. Should have done it a long time ago but that is my fault not the dealers.
 

Don in Lodi

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Cycledude said:
What o ring recall ?
The first few dozen 12's that came in may or may not have had their fuel pump o-ring twisted in the installation. It would have been taken care of by the dealership before a sale after a point. A small fuel leak was the symptom. A small span of vin #'s involved. Mine wasn't twisted. My light harness did fry.
 

AVGeek

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My 12 is outside of the VIN range for the headlight recall, and I haven't had any issues. I did have the O-Ring recall done, but mine wasn't twisted.
 
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